Remove/install valve block

AR07.03-P-1020M

Remove/install valve block

17.12.09

29.4.03

Repair method has been revised

25.9.03

Value changed from 20 Nm to 23 Nm

Value in series 1001 changed for engine 628.960/961/962/963

*BA07.16-P-1001-01C

25.9.03

Value changed from 20 Nm to 23 Nm

Value in series 1009 changed for engine 628.960/961/962/963

*BA07.16-P-1009-01C

 

Remove/install

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Turn key in electronic ignition switch control unit to position "0"

 Vehicles with Keyless-Go Code 889: Press Start/Stop button repeatedly until ignition is switched off.

2

Open engine hood and raise to vertical position

Model 220

AR88.40-P-1000M

MODEL 463

AR88.40-P-1000GG

3

Remove air filter housing

Model 220

AR09.10-P-1050M

Model 463

AR09.10-P-1050GD

4.1

Remove front engine cover

Model 220

AR01.10-P-2405M

4.2

Remove panelling for the oil filler plug

Model 463

5

Remove fuel filter (70)

AR47.20-P-5510M

6

Disconnect electrical connector on rail pressure sensor (B4/6) and at pressure regulator valve (Y74)

7

Remove fuel high pressure lines (1, 2, 3)

 When working on injection system ensure scrupulous cleanliness!

Close off connections for the fuel high pressure lines (1, 2, 3) immediately after removal as a protection against contamination. Do not crush or bend fuel high pressure lines (1, 2, 3). Counterhold the connection fittings for the fuel high pressure lines (1, 2, 3) using a suitable tool.

 Installation: Check sealing cone for fuel high pressure lines (1, 2, 3); replace fuel high pressure lines (1, 2, 3) if there are pressure marks.

 Nut of pressure line to valve block/ high pressure pump

*BA07.16-P-1001-01C

 Nut, pressure line to valve block/ rail

*BA07.16-P-1009-01C

 Bolt, retaining clamp of high-pressure line to charge air manifold

*BA07.16-P-1015-01C

Box wrench bit

*000589770300

 Set of plugs

*129589009100

8

Remove banjo bolt (4) and connector (4a) for return lines

 Installation: Install new sealing rings (4b).



*BA07.16-P-1005-01C

9

Remove bolts (5) and valve block (21/7) with the attached fuel return line (6) in direction of travel

 Installation: For stress-assembly the fuel high pressure lines (1, 2, 3) must be put in place handtight before tightening the screws (5).



*BA07.16-P-1014-01C

10

Close off fuel return line (6) on valve block (21/7)

 Installation: Replace O-ring.

AR07.03-P-1020-01TD

11

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving 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 from 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-0001-01A

12

Check fuel system for leaks with engine running

13

Read out fault memory

STAR DIAGNOSIS diagnosis system



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Engine 628.960/962/963

BA07.16-P-1001-01C

Nut, pressure line to valve block/ high pressure pump

Nm

23

BA07.16-P-1005-01C

Banjo bolt, leak oil line to valve block

Nm

20

BA07.16-P-1009-01C

Nut, pressure line to valve block/ rail

Nm

23

BA07.16-P-1014-01C

Valve block on charge air manifold

Nm

12

BA07.16-P-1015-01C

Bolt, retaining clamp of high-pressure line to charge air manifold

Nm

8