Remove/install nozzle holder combination

AR07.03-G-6831CH

Remove/install nozzle holder combination

21.11.2018

Model

000.001 with engine 457.9, 458.9

Modification notes

20.11.2018

Work procedure completely revised.

1

Screw

4

Connection fitting

6.1

O-ring

2

Retaining clip

5

O-ring

10

Sealing sleeve

3

Pressure screw

6

Nozzle holder combination

L

Shank length

6

Nozzle holder combination

7

Threaded insert

8

Impact extractor

Only if the sealing sleeve (10) has remained stuck in place

8

Impact extractor

9.1

Pull-off device (clamping drift)

9.2

Extraction tool

10

Sealing sleeve

Only if reinstalling the used nozzle holder combination (6)

6

Nozzle holder combination

11.1

Assembly tool (for sealing sleeve)

10

Sealing sleeve

11.2

Assembly tool (for nozzle holder head)

 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

 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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-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

Remove charge-air distributor.

AR09.41-G-8681CH

2

Remove cylinder head cover.

AR01.20-G-5014CH

3

Remove injection line.

AR07.15-G-8971CH

4

Unscrew pressure screw (3) and remove connection fitting (4).

5

Unscrew screw (1) and remove clamping bracket (2).

6

Attach threaded insert (7) using impact extractor (8) to mount of nozzle holder assembly (6).

 Threaded insert

*904589006300

 Impact extractor

*355589016300

7

Pull out nozzle holder assembly (6) using impact extractor (8).

 Do not disassemble the nozzle holder assembly (6).

8

Remove threaded insert (7) and impact extractor (8) from nozzle holder assembly (6).

9

Replace nozzle holder combination (6).

Only if required.

10

Remove O-ring (6.1) at nozzle holder assembly (6).

Only where nozzle holder assembly (6) is reused.

11

Remove sealing sleeve (10) from nozzle holder assembly (6).

Only where nozzle holder assembly (6) is reused.

12

Remove sealing sleeve (10) using pull-off device (9.1, 9.2) and impact extractor (8) from cylinder head.

Only for a stuck sealing sleeve (10) in the cylinder head.

 Extraction tool

*906589026300

 Impact extractor

*355589016300

13

Clean combustion residues from nozzle holder assembly (6) and contact surface for sealing sleeve (10).

Only where nozzle holder assembly (6) is reused.

 Clean contact surface for sealing sleeve (10) using a brass brush.

14

Check nozzle holder assembly (6) for wear via a visual check.

Only where nozzle holder assembly (6) is reused.

If wear can be detected,



Replace nozzle holder combination (6).



Install

15

Measure shank length (L) of screw (1).

Screw/bolt, retaining clip, nozzle holder combination and constant throttle to cylinder head

*BE07.03-N-1002-01K

If permissible shank length (L) is exceeded,



Replace screw/bolt (1).

16

Press new sealing sleeve (10) onto nozzle holder assembly (6) using assembly tool (11.1, 11.2).

Only where nozzle holder assembly (6) is reused.

 Assembly tool

*906589036300

17

Insert new O-ring (6.1) on nozzle holder assembly (6).

Only where nozzle holder assembly (6) is reused.

18

Coat O-ring (6.1) of nozzle holder assembly (6) with high-temperature grease.

High-temperature grease

*BR00.45-Z-1051-06A

19

Insert new O-ring (5) on connection fitting (4) and coat with high-temperature grease.

High-temperature grease

*BR00.45-Z-1051-06A

20

Install nozzle holder assembly (6) and position clamping bracket (2).

 Align nozzle holder assembly (6) with bore of connection fitting (4).

21

Wet connection fitting (4) in area of sealing cone with clean engine oil.

22

Insert connection fitting (4) in cylinder head and press in until this engages in fuel bore of nozzle holder assembly (6).

 If necessary, twist the nozzle holder combination (6) and the retaining clamp (2) in the cylinder head.

23

Tighten clamping bracket (2) using screw (1).

 Bolt, retaining clip, nozzle holder combination and constant throttle to cylinder head

*BA07.15-N-1007-01F

24

Tighten connection fitting (4) using pressure screw (3).

 Thrust bolt, connection fitting to cylinder head

*BA07.15-N-1004-01F

25

Install injection line.

AR07.15-G-8971CH

26

Install cylinder head cover.

AR01.20-G-5014CH

27

Install charge-air distributor.

AR09.41-G-8681CH

28

Perform engine test run.

 Run engine for approx. 1 minute.
The fuel system is bled automatically.

29

Check engine in area of injection line and connection fitting (4) for leaks.

 Visual inspection.

Test and adjustment values of injection nozzles

Number

Designation

ENGINE 457.9, 458.9, 541.9, 542.9, 941.9, 942.9

BE07.03-N-1002-01K

Screw/bolt, retaining clip, nozzle holder combination and constant throttle to cylinder head

Shank length

mm

91

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

Number

Designation

Engine 457.9, 458.9 in model 000.001

BA07.15-N-1004-01F

Thrust bolt, connection fitting to cylinder head

Nm

45

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

Number

Designation

Engine 457.9, 458.9 in model 000.001

BA07.15-N-1007-01F

Bolt, retaining clip, nozzle holder combination and constant throttle to cylinder head

Nm

50

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-06A

High-temperature grease

A 000 989 81 51