Remove/install nozzle holder combination

AR07.03-W-6831B

Remove/install nozzle holder combination

11.05.2016

Engine

541.9 in model 950, 952, 953, 954

Engine

542.9 in model 950, 952, 954

Modification notes

26.02.2016

Thrust bolt, connection fitting to cylinder head

BA07.15-N-1005-01B

02.05.2016

Work procedure completely revised.

Shown on engine 541.9

1

Injection line

2

Leak fuel line

3

Pressure screw

4

O-ring

5.1

Connection fitting with anti-twist lock (press in ball)

5.2

Connection fitting without anti-twist lock

6

Nozzle holder combination

7

O-ring

8

Screw/bolt

9.1

Retaining clip (up to engine end number 106096)

9.2

Retaining clip (from engine end number 106097)

10.1

Sealing ring (up to engine end number 197928)

10.2

Sealing sleeve (as of engine end number 197929)

11

Constant throttle cap

12

Threaded insert

13

Impact extractor

L

Shank length

1

Injection line

3

Pressure screw

4

O-ring

5.1

Connection fitting with anti-twist lock (press in ball)

5.2

Connection fitting without anti-twist lock

6

Nozzle holder combination

7

O-ring

8

Screw/bolt

9.1

Clamp (up to engine end number 106096)

9.2

Clamp (as of engine end number 106097)

10.1

Sealing ring (up to engine end number 197928)

10.2

Sealing sleeve (as of engine end number 197929)

11

Constant throttle cap

Pfeil

Groove

Only as of engine end number 197929

6

Nozzle holder combination

10.2

Sealing sleeve (as of engine end number 197929)

14.1

Assembly tool (for nozzle holder head)

14.2

Assembly tool (for sealing sleeve)

 Danger !

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

 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



Remove

1

Remove cylinder head cover

AR01.20-W-5014B

2

Detach leak fuel line (2) at cylinder head

3

Remove injection line (1)

AR07.15-W-9235B

4

Unscrew pressure screw (3) and remove pressure pipe connection with anti-twist lock (5.1) or pressure pipe connection without anti-twist lock (5.2)

5

Remove tensioning clamp (9.1 or 9.2)

6

Attach the threaded insert (12) to the nozzle holder combination (6) with an impact extractor (13)

 Impact extractor

*355589016300

 Threaded insert

*904589006300

7

Remove the nozzle holder combination (6) with an impact extractor (13)

 Do not disassemble nozzle holder combination (6).

 Impact extractor

*355589016300

8

Remove threaded insert (12) and impact extractor (13) at the nozzle holder combination (6)

 Impact extractor

*355589016300

 Threaded insert

*904589006300

9.1

Remove sealing ring (10.1) at nozzle holder combination (6)

Up to engine end number 197928

9.2

Pull off sealing sleeve (10.2) at nozzle holder combination (6)

As of engine end number 197929

10

Pull sealing sleeve (10.2) out of cylinder head

Only as of engine end number 197929.
Only for a stuck sealing sleeve (10.2) in the cylinder head.

 Impact extractor

*355589016300

 Extraction tool

*906589026300

11

Clean nozzle holder combination (6), contact surface of sealing ring (10.1) or the sealing sleeve (10.2) using a brass brush from combustion residues

Only when reinstalling used nozzle holder combination (6).

12

Check nozzle holder combination (6) by means of visual inspection

For wear or a complaint about a poor engine power.



Replace nozzle holder combination (6).



Install

13

Measure shank length (L) of screw/bolt (8)

Screw/bolt, tensioning arm of nozzle holder combination/constant throttle to cylinder head

*BE07.03-N-1002-01B

If the max. shank length (L) is exceeded.



Replace screw/bolt (8).

 As a general rule, screw/bolts with MB standard 10105 must be replaced with screw/bolts with MB part no. on the bolt head.

14

Insert new O-ring (7) at nozzle holder combination (6)

Only when reinstalling used nozzle holder combination (6).

15

Coat the O-ring (7) with a little high-temperature grease

High-temperature grease

*BR00.45-Z-1051-06A

16.1

Place new sealing ring (10.1) on nozzle holder combination (6)

Up to engine end number 197928

 Pay attention to installation location: The small ring surface on the sealing ring (10.1) must point towards the nozzle holder combination (6).

16.2

Press new sealing sleeve (10.2) onto nozzle holder combination (6) with assembly tool (14.1, 14.2)

As of engine end number 197929

 Assembly tool

*906589036300

17

Check connection fitting with anti-twist lock (5.1) or connection fitting without anti-twist lock (5.2) through visual inspection for damage or replace

 A damaged connection fitting with anti-twist lock (ball pressed in) (5.1) can be replaced by the modified connection fitting without anti-twist lock (5.2).

18

Coat O-ring (4) lightly with high-temperature grease and coat connection fitting with anti-twist lock (5.1) or connection fitting without anti-twist lock (5.2) around the sealing cone with engine oil

High-temperature grease

*BR00.45-Z-1051-06A

19

Position new O-ring (4) to the connection fitting with anti-twist lock (5.1) or connection fitting without anti-twist lock (5.2)

20

Install nozzle holder assembly (6) and position retaining clip (9.1 or 9.2)

 Align nozzle holder assembly (6) for rough pressure pipe connection hole.

21

Insert connection fitting with anti-twist lock (5.1) or connection fitting without anti-twist lock (5.2) in the cylinder head, and press in until it latches into the fuel hole of the nozzle holder combination (6)

 If necessary twist nozzle holder assembly (6) under retaining clip (9.1 or 9.2) in cylinder head.
Connection fitting with anti-twist lock (pressed-in ball) (5.1) must not be installed in a cylinder head without groove (arrow). The ball must be inserted into the groove (arrow).

22

Tighten the retaining clip (9.1 or 9.2) with a screw/bolt (8)

 Bolt, tensioning arm of injection nozzle and constant throttle to cylinder head

*BA07.15-N-1003-01B

23

Tighten connection fitting with anti-twist lock (5.1) or pressure pipe connection without anti-twist lock (5.2) with the pressure screw (3)

 Thrust bolt, connection fitting to cylinder head

*BA07.15-N-1005-01B

24

Install injection line (1)

AR07.15-W-9235B

25

Install leak fuel line (2)

 Leak fuel line to cylinder head

*BA01.30-N-1004-01D

26

Install cylinder head cover

AR01.20-W-5014B

Check and adjustment values of injection nozzles

Number

Designation

Engine 541.9, 542.9

BE07.03-N-1002-01B

Screw/bolt, tensioning arm of nozzle holder combination/constant throttle to cylinder head

Permissible shank length

mm

91

 Cylinder head

Number

Designation

ENGINE 541.9, 542.9

BA01.30-N-1004-01D

Leak fuel line to cylinder head

Nm

15

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

Number

Designation

Engine 541.9, 542.9

BA07.15-N-1003-01B

Bolt, tensioning arm of injection nozzle and constant throttle to cylinder head

Nm

50

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

Number

Designation

Engine 541.9, 542.9

BA07.15-N-1005-01B

Thrust bolt, connection fitting to cylinder head

Nm

45

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-06A

High-temperature grease

A 000 989 81 51