Remove/install nozzle holder combination

AR07.03-B-6831A

Remove/install nozzle holder combination

05.03.2020

Engine

904 in model 688.2

Engine

904, 906, 924, 926 in model 382.1, 685.282/284/289/290, 688.2

Engine

904.925 in model 693

Engine

906, 926 in model 693.3

1

Nozzle holder with injection nozzle

9

Injector Pressure Line, Intern

2

Puller

10

Pressure screw

3

Bolt

11

Injector pressure line

4

Injector bracket mounting

12

Constant Throttle Closing Cover

5

O-ring

13.1

Base for Mounting Seal on Injector (Engine 906.9, 924.9, 926.9)

6

Seal Washer (engine 904.9)

13.2

Bushing for Mounting Seal on Injector (Engine 906.9, 924.9, 926.9)

7

Thermal Insulation Cover/Seal (engine 906.9, 924.9, 926.9)

14

Vise

8

O-ring



Remove

1

Remove the cylinder head cover

.

AR01.20-B-5014B

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

2

Remove the injection tube (11)

.

AR07.15-B-9235A

 Cover connections in the injection unit and injector holder.

3

Remove the bolt (10) and the intern pressure line (9)

4

Remove the bolt (3) and the mounting bracket (4) from the nozzle holder (1)

5

Remove the nozzle holder (1) with the slide hammer puller


When removing the nozzle holder, do not rotate it so as not to compromise the set values. Do not disassemble the nozzle holder (1).
In case of irregularity, replace the entire nozzle holder (1).

 Use the threaded adapter in nozzle holder to the slide hammer puller installation.

 Threaded insert

*904589006300

 Impact extractor

*355589016300

6

Remove the puller (2) from the injector holder (1)

 Protect the injector holder against impurities.

7

Remove the seal (6, 7) from the nozzle holder (1)

 If the seal (7) is stuck in the head, use the pulling device.

 Extraction tool

*906589026300

 Impact extractor

*355589016300



Install

8

Check the tapered hole in the nozzle holder (1) for wear and the cone at the end of the internal pressure line (9) for wear or cracking

 In case of irregularities, replace the pipe line (9) and/or the nozzle holder (1) to ensure leak tightness.

9

Clean the seal contact surface on the nozzle holder (1)

 Do not use a wire brush to clean the injection nozzle.
Carry out ultrasound cleaning.

10

Install the new seal washer (6) on the nozzle holder (1)

Engine 904

 The smallest surface area of ​​the washer (6) should face the nozzle holder.

11

Install the new thermal insulation cover/seal (7) on the nozzle holder (1)

 Correctly position seal (7) on injector (1) and install under pressure using base (13.1), bushing (13.2) and vise (14).

 Assembly tool

*906589036300

12

Install the new thermal insulation cover/seal (7) on the nozzle holder (1)

 Correctly position seal (7) on injector (1) and install under pressure using base (13.1), bushing (13.2) and vise (14).

 Assembly tool

*906589036300

13

Replace the O-ring (5) on the nozzle holder (1)

 Lubricate the O-ring (5) with engine oil.

14

Install the nozzle holder (1) on the cylinder head

 The correct nozzle holder (1) positioning in relation to the internal pressure line (9) is ensured by the mounting bracket (4).

15

Install the mounting bracket (4) on the nozzle holder and the bolt (3)

 .Attachment support of the cylinder head injector

*BA07.15-B-1003-01A

16

Replace O-ring (8) on internal pressure line (9)

 Lubricate the O-ring (8) with engine oil.

17

Install the internal pressure line (9) and tighten y=the bolt (10)

 Pay attention to the correct positioning of the pressed ball (arrow) in the pressure line (9) previous version, in the slot (arrow) in the head. The current version of the pressure line (9) does not contain the ball.

 Apply the sealant to screw thread (10).

 .Injector pressure pipe, inside the cylinder head

*BA07.15-B-1005-01A

Sealant Loctite 574, 50 ml

*BR00.45-Z-1009-01A

18

Install the injection tube (11)

.

AR07.15-B-9235A

19

Install cylinder head cover

.

AR01.20-B-5014B

 Diesel injection system with injection unit (MR/PLD)

Number

Designation

Engine 904.9, 906.9, 924.9, 926.9

BA07.15-B-1003-01A

Attachment support of the cylinder head injector

12 corners with spheric collar

Nm

35

Inside hexagonal

Nm

30

 Diesel injection system with injection unit (MR/PLD)

Number

Designation

Engine 904.9, 906.9, 924.9, 926.9

BA07.15-B-1005-01A

Injector pressure pipe, inside the cylinder head

Nm

40...45

Repair materials

Number

Designation

Order number

BR00.45-Z-1009-01A

Sealant Loctite 574, 50 ml

A 001 989 89 20 10