Remove/install high-pressure line to rail

AR07.16-G-1004HA

Remove/install high-pressure line to rail

14.01.2019

Engine

470.9, 471.9## ## as of 032691, 473.9 in model 800.310/320

Shown on engine 470.9

1

High pressure pipe

2

High pressure pipe

3

Vibration damper

4

Rail

5

Clip

6

Bracket

7

Screw

8

Fuel system high pressure pump

A

Angle (approx. 15 °)

Shown on engine 471.9

1

High pressure pipe

2

High pressure pipe

3

Vibration damper

4

Rail

5

Clip

6

Bracket

7

Screw

8

Fuel system high pressure pump

A

Angle (about 15 °)

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01B

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW



Remove

1

Clean engine in area of high-pressure lines (1, 2)

2

Remove resonator

Only on engine 471.9, 473.9

AR13.10-G-5840HA

3

Remove screw/bolt (7)

4

Remove high-pressure lines (1, 2) with bracket (6)

 Counterhold fitting on fuel system high pressure pump (8).

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

5

Remove clamps (5) on bracket (6)

6

Remove vibration damper (3) from high-pressure lines (1, 2)



Install

7

Attach bracket (6) to rail bracket (4) loosely

8

Place clamp for the return lines with screw/bolt (7) on bracket (6)

9

Check vibration damper (3) for wear

If wear is present,



replace the vibration damper (3).

10

Attach vibration damper (3) to the high-pressure lines (1, 2)

 In doing so, maintain the angle (A) at about 15 °.

11

Loosely place high-pressure lines (1, 2) on rail (4) and on the fuel system high pressure pump (8)


The removed high-pressure lines (1, 2) must always be replaced.
Leaks can occur otherwise.

12

Check the elastomers of clamps (5) for wear

If wear is present,



replace the clamp (5).

13

Loosely place clamps (5) on bracket (6)

14

Install new high-pressure lines (1, 2) on rail (4) and fasten to the fuel system high pressure pump (8), while counteholding the fitting at the fuel system high pressure pump (8)

 Union nut, high-pressure line to rail

*BA07.16-N-1003-03A

 Union nut, high-pressure line to fuel high-pressure pump

*BA07.16-N-1004-03A

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

15

Tighten down bracket (6) to rail bracket (4)

 Bolt, bracket for high-pressure line to rail bracket

*BA07.16-N-1040-03A

16

Fasten clamp for the return lines with screw/bolt (7) on bracket (6)

17

Tighten clamps (5) on bracket (6)

 Counterhold clamps (5) when tightening. The clamps (5) must be exactly aligned to the high-pressure lines (1, 2).

 Bolt, high-pressure line clamp to bracket

*BA07.16-N-1007-03A

18

Install resonator

Only on engine 471.9, 473.9

AR13.10-G-5840HA

19

Start engine and perform an engine test run

 Allow engine to run at a higher rotational speed.

If engine fails to start or only runs for a brief period.



Fill fuel low-pressure circuit.

AR07.16-G-1007H

20

Check area around the high-pressure lines (1, 2) for leaktightness

 Visual inspection.

21

Turn off engine

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1003-03A

Union nut, high-pressure line to rail

Nm

40

40

 Common rail diesel injection system

Number

Designation

Engine 473.9

BA07.16-N-1003-03A

Union nut, high-pressure line to rail

Nm

40

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1004-03A

Union nut, high-pressure line to fuel high-pressure pump

Nm

40

40

 Common rail diesel injection system

Number

Designation

Engine 473.9

BA07.16-N-1004-03A

Union nut, high-pressure line to fuel high-pressure pump

Nm

40

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1007-03A

Bolt, high-pressure line clamp to bracket

Nm

15

15

 Common rail diesel injection system

Number

Designation

Engine 473.9

BA07.16-N-1007-03A

Bolt, high-pressure line clamp to bracket

Nm

15

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1040-03A

Bolt, bracket for high-pressure line to rail bracket

M6

Nm

15

15

M8

Nm

30

30

 Common rail diesel injection system

Number

Designation

Engine 473.9

BA07.16-N-1040-03A

Bolt, bracket for high-pressure line to rail bracket

M6

Nm

15

M8

Nm

30