Fuel supply system - diesel engines

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety regulations for working on fuel supply
  1
• 1.2 Safety measures when working on vehicles with a start/stop system
  2
• 1.4 Safety precautions when working on SCR system
  2
• 2 Identification
  4
• 2.1 Engine number/engine data
  4
• 3 General information
  5
• 3.1 Rules for cleanliness when working on auxiliary heater and fuel system
  5
• 4 Repair instructions
  6
• 4.1 Rules for cleanliness
  6
• 4.2 Foreign objects in engine
  6
• 4.3 Contact corrosion
  6
• 4.4 Routing and attachment of lines
  7
• 4.5 Fitting radiator and condensers
  7
• 4.6 Adapting learnt value for SCR system
  7
• Fuel supply system
  8
• 1 Procedure in event of misfuelling
  8
• 1.1 Step 1, engine was started with incorrect fuel
  8
• 1.2 Step 2, engine was not started with incorrect fuel
  10
• 1.3 Step 3, there are metal particles in fuel delivery unit and fuel tank
  12
• 1.4 Step 4, there are no metal particles in fuel delivery unit or fuel tank
  13
• 1.5 Step 5, there are metal particles in high-pressure pump
  14
• 1.6 Step 6, there are no metal particles in high-pressure pump
  14
• 2 Fuel
  16
• 2.1 Assembly overview - fuel tank
  16
• 2.2 Removing and installing fuel tank
  23
• 2.3 Emptying fuel tank
  46
• 2.4 Removing and installing misfuelling prevention device
  61
• 2.5 Deactivating misfuelling prevention device
  65
• 3 Fuel delivery unit, fuel gauge sender
  67
• 3.1 Assembly overview - fuel delivery unit/fuel gauge sender
  67
• 3.2 Removing and installing fuel delivery unit, fuel gauge sender
  75
• 3.3 Removing and installing fuel gauge sender G
  86
• 3.4 Removing and installing fuel gauge sender 2 G169
  87
• 3.5 Removing and installing assembly opening cover
  93
• 4 Plug-in connectors
  95
• 4.1 Separating plug-in connectors
  95
• 5 Fuel filter
  102
• 5.1 Assembly overview – fuel filter
  102
• 5.2 Removing and installing fuel filter
  106
• 5.3 Fuel hoses in the engine compartment
  110
• 5.4 Drain water from fuel filter
  111
• 6 Accelerator pedal
  113
• 6.1 Assembly overview - accelerator module
  113
• 6.2 Removing and installing accelerator pedal module GX2
  113
• 7 Fuel supply
  115
• 7.1 Checking fuel system pressurisation pump G6
  115
• 7.2 Removing and installing suction-jet pump
  132
• 7.3 Removing and installing fuel pump control unit J538
  137
• 7.4 Checking suction-jet pump
  139
• 8 Senders and sensors
  141
• 8.1 Removing and installing water separator sender G63
  141
• 9 Lines
  143
• 9.1 Removing and installing fuel lines
  143
• 9.2 Removing and installing fuel line for auxiliary/supplementary heater
  148