Remove/install nozzle holder combination

AR07.03-W-6831D

Remove/install nozzle holder combination

11.05.2016

Engine

457.9 in model 374, 375, 940, 942, 943, 944, 958

Modification notes

02.05.2016

Work procedure completely revised.

1

Pressure screw

2

Connection fitting

3

O-ring

4

Screw/bolt

5

Retaining clip

6

Nozzle holder combination

7

O-ring

8

Sealing sleeve

9

Cap

L

Shank length

Pfeil

Support

6

Nozzle holder combination

8

Sealing sleeve

10.1

Assembly tool (for nozzle holder head)

10.2

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 charge air distributor

AR09.41-W-8681D

2

Remove cylinder head cover

AR01.20-W-5014C

3

Remove injection line

AR07.15-W-9235C


The injection line must not be bent.
Otherwise the coating comes off in the injection line and engine damage occurs.

4

Remove pressure screw (1) and remove connection fitting (2)

5

Remove clamp (5)

6

Install threaded insert with impact extractor on nozzle holder assembly (6) (arrow) of the nozzle holder assembly

 Impact extractor

*355589016300

7

Pull out nozzle holder assembly (6) using impact extractor

 Do not disassemble nozzle holder combination (6).

 Impact extractor

*355589016300

 Threaded insert

*904589006300

8

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

 Impact extractor

*355589016300

 Threaded insert

*904589006300

9

Pull off sealing sleeve (8) at nozzle holder combination (6)

Only when reinstalling used nozzle holder combination (6).

10

Pull sealing sleeve (8) out of cylinder head

Only for a stuck sealing sleeve (8) in the cylinder head.

 Impact extractor

*355589016300

 Extraction tool

*906589026300

11

Clean nozzle holder combination (6) and contact surface free from combustion residues on the sealing sleeve (8) using a brass brush

Only when reinstalling used nozzle holder combination (6).

12

Check nozzle holder combination (6) for damage 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 (4)

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 (4).

14

Press new sealing sleeve (8) onto nozzle holder combination (6) with assembly tool (10.1, 10.2)

Only when reinstalling used nozzle holder combination (6).

 Assembly tool

*906589036300

15

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

Only when reinstalling used nozzle holder combination (6).

16

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

High-temperature grease

*BR00.45-Z-1051-06A

17

Lightly coat O-ring (3) with high-temperature grease and moisten connection fitting (2) around the sealing cone with engine oil

High-temperature grease

*BR00.45-Z-1051-06A

18

Install a new O-ring (3) on connection fitting (2)

19

Install nozzle holder assembly (6) and position retaining clip (5)

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

20

Insert connection fitting (2) into cylinder head and press in until it engages in the fuel hole of the nozzle holder combination (6)

 If necessary, use retaining clip (5) to turn nozzle holder combination (6) in cylinder head.

21

Tighten retaining clamp (5) with screw/bolt (4)

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

*BA07.15-N-1006-01G

22

Tighten connection fitting (2) with pressure screw (1)

 Thrust bolt, connection fitting to cylinder head

*BA07.15-N-1004-01G

23

Install injection line

AR07.15-W-9235C


The injection line must not be bent.
Otherwise the coating comes off in the injection line and engine damage occurs.

24

Install cylinder head cover

AR01.20-W-5014C

25

Install charge air distributor

AR09.41-W-8681D

Check and adjustment values of injection nozzles

Number

Designation

Engine 457.9

BE07.03-N-1002-01B

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

Permissible shank length

mm

91

 Diesel injection system with unit pumps (MR)

Number

Designation

Engine 457.9

BA07.15-N-1004-01G

Thrust bolt, connection fitting to cylinder head

Nm

45

 Diesel injection system with unit pumps (MR)

Number

Designation

Engine 457.9

BA07.15-N-1006-01G

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