Remove/install MR/PLD injection lines

AR07.15-W-9235S

Remove/install MR/PLD injection lines

24.11.2015

Engine

457.9 in model 949

Modification notes

15.12.2015

Union nut, injection line to connection fitting/unit pump

BA07.15-N-1003-01G

26.02.2016

Thrust bolt, connection fitting to cylinder head

BA07.15-N-1004-01G

1

Injection lines

2

Connection fitting pressure screws

 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

 Danger !

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



Remove

1

Open engine hood and raise to vertical position

AR88.40-W-1000R

2

Remove front section of front left fender

AR88.10-W-1500RE

3

Remove trim on front end

AR88.30-W-2301S

4

Drain coolant until the expansion reservoir is emptied

AR20.00-W-1142S

5

Remove expansion reservoir with carrier

AR20.30-W-4950-01S

6

Remove left charge air pipe

AR09.41-W-1327S

7

Remove charge air distributor

AR09.41-W-8683S

8

Mark injection lines (1) relative to the corresponding cylinder

9

Remove injection line (1)


Injection lines (1) must not be bent.
Otherwise the coating comes off in the injection lines (1) and engine damage occurs.

 Close off bores on the connection fitting and the unit pumps.

 Box wrench bit

*000589680300

 Ring wrench

*000589070300



Install

10

Tighten connection fitting pressure screw (2) on cylinder head

 Thrust bolt, connection fitting to cylinder head

*BA07.15-N-1004-01G

11

Install injection lines (1)


Injection lines (1) must not be bent.
Otherwise the coating comes off in the injection lines (1) and engine damage occurs.

 Pay attention to the marking of the injection lines (1).

 Union nut, injection line to connection fitting/unit pump

*BA07.15-N-1003-01G

 Box wrench bit

*000589680300

 Ring wrench

*000589070300

12

Install charge air distributor

AR09.41-W-8683S

13

Install left charge air pipe

AR09.41-W-1327S

14

Install expansion reservoir with carrier

AR20.30-W-4950-01S

15

Pour in coolant

AR20.00-W-1142S

16

Start the engine and bleed the fuel system

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

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



Bleed fuel system

AR47.00-W-1720S

17

Check threaded connections on injection lines (1) for leaktightness

In case of leaky injection lines (1)



Replace the affected injection line (1)

18

Turn off engine

19

Install trim at front end

AR88.30-W-2301S

20

Install front section of fender on the left

AR88.10-W-1500RE

21

Close engine hood

AR88.40-W-1000R

 Diesel injection system with unit pumps (MR)

Number

Designation

Engine 457.9

BA07.15-N-1003-01G

Union nut, injection line to connection fitting/unit pump

without code MS7 (BlueTec EEV)

Nm

30

with code MS7 (BlueTec EEV)

Nm

35

 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