Attach/detach test adapter to XENTRY for guided measurement for return quantity of pressure limiting valve

AR07.16-G-0160N

Attach/detach test adapter to XENTRY for guided measurement for return quantity of pressure limiting valve

10.04.2019

Engine

471.9## ## up to 032690 in model 800.110/112

Modification notes

10.10.2018

Work procedure completely revised.

Shown with front expansion reservoir

1

Resonator

3

Compressor air intake duct

5

Fuel line (nozzle needle valve return line)

2

Compressor air intake duct

4

Bracket

6

Fuel line (pressure limiting valve return line)

5

Fuel line (nozzle needle valve return line)

6

Fuel line (pressure limiting valve return line)

7.1

Plug

7.2

Test adapter

 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

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

Notes on safety-relevant components

AH00.00-Z-0019-01A

Installing

1

Clean engine in area of fuel filter module and fuel lines (5, 6).

2

Remove the resonator box (1).

AR13.10-G-5840N

3

Disconnect air intake line for compressor (3) from compressor.

4

Remove bracket (4).

5

Remove fuel line (5) from threaded fittings of cylinder head and fuel filter module.


When detaching the fuel line (5) counterhold the threaded fitting on the cylinder head using the  counterholder.
Otherwise the fuel line (5) may be damaged.

 Collect fuel which runs out in a suitable container.

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

 Counterholder

*470589000100

6

Remove fuel line (6) from fuel filter module and rail.

 Collect fuel which runs out in a suitable container.

 Box wrench socket

*314589010300

7

Install stop plug (7.1) on fuel filter module.

 Stop plug to fuel filter module

*BA07.16-N-1036-03A

 Box wrench socket

*314589010300

 Test adapter

*470589022100

8

Connect test adapter (7.2) to rail.

 Banjo bolt, test adapter to rail

*BA07.16-N-1039-03A

 Test adapter

*470589022100

9

Connect test adapter (7.2) to measuring tank.

 Test adapter

*470589022100

10

Install fuel line (5) on threaded fittings of cylinder head and fuel filter module.

 Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting

*BA07.16-N-1019-03A

 Union nut, fuel line (nozzle needle valves return) to fuel filter module pressure regulating valve

*BA07.16-N-1020-03A

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

Remove

11

Remove fuel line (5) from threaded fittings of cylinder head and fuel filter module.

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

 Counterholder

*470589000100

12

Remove test adapter (7.2) from measuring tank.

13

Remove test adapter (7.2) from rail.

14

Remove stop plug (7.1) from fuel filter module.

 Box wrench socket

*314589010300

15

Attach fuel line (6) to fuel filter module and rail.

 Replace sealing rings on the rail.

 Union nut, fuel line from rail (pressure limiting valve return) to fuel filter module

*BA07.16-N-1023-03A

 Banjo bolt, fuel line to rail (pressure limiting valve return)

*BA07.16-N-1024-03A

 Box wrench socket

*314589010300

16

Install fuel line (5) on threaded fittings of cylinder head and fuel filter module.

 Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting

*BA07.16-N-1019-03A

 Union nut, fuel line (nozzle needle valves return) to fuel filter module pressure regulating valve

*BA07.16-N-1020-03A

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

17

Replace bracket (4) and high-pressure lines to rail.

AR07.16-G-1004N

 The bracket (4) and the high-pressure line to the rail must not be reused. They must be replaced together with the clamps and the vibration dampers.

18

Attach air intake line for compressor (3) to compressor.

19

Install resonator box (1).

AR13.10-G-5840N



Check

20

Start engine and perform an engine test run.

 Allow the engine to run at a higher engine speed.
See information from body manufacturer.

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



Fill fuel low-pressure circuit.

AR07.16-G-1007N

21

Check area of fuel filter module and fuel lines (5, 6) in terms of leak tightness and switch off engine.

 Visual inspection.

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1019-03A

Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting

M16x1.5

Nm

25

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1020-03A

Union nut, fuel line (nozzle needle valves return) to fuel filter module pressure regulating valve

M16x1.5

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1023-03A

Union nut, fuel line from rail (pressure limiting valve return) to fuel filter module

M16x1.5

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1024-03A

Banjo bolt, fuel line to rail (pressure limiting valve return)

M14x1.5

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1036-03A

Stop plug to fuel filter module

M16x1.5

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1039-03A

Banjo bolt, test adapter to rail

M14x1.5

Nm

30