Remove/install high-pressure line to rail

AR07.16-G-1004NA

Remove/install high-pressure line to rail

14.01.2019

Engine

470.9, 471.9## ## as of 032691 in model 800.110/112

Modification notes

04.10.2018

Work procedure completely revised.

Shown on engine 470.9

1

High pressure pipe

2

High pressure pipe

3

Vibration damper

4

Rail

5

Clip

6

Bracket

7

Screw

8

Fuel system high pressure pump

A

Angle (approx. 15°)

Shown on engine 471.9. as of engine end number 032691

1

High pressure pipe

2

High pressure pipe

3

Vibration damper

4

Rail

5

Clip

6

Bracket

7

Screw

8

Fuel system high pressure pump

A

Angle (approx. 15°)

 Danger

Risk of explosion caused by 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-0001-01B

 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 self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Notes on safety-relevant components

AH00.00-Z-0019-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW



Remove

1

Switch off ignition.

2

Clean engine in area of high-pressure lines (1, 2).

3

Remove resonator box.

Only for engine 471.9

AR13.10-G-5840N

4

Remove screw (7).

5

Remove high-pressure lines (1, 2) with bracket (6).

 Counterhold fittings of high-pressure lines (1, 2) on fuel high-pressure pump (8).

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

6

Remove clamps (5) on bracket (6).



Install

7

Loosely position bracket (6) on rail bracket (4).

8

Loosely position clamp for return lines with screw (7) on bracket (6).

9

Check vibration dampers (3) for wear.

If wear is detected:



Replace affected vibration damper (3).

10

Attach vibration dampers (3) to new high-pressure lines (1, 2).

 When doing so, maintain angle (A) of approx. 15°.

11

Loosely position new high-pressure lines (1, 2) on rail (4) and on fuel high-pressure pump (8).


The removed high-pressure lines (1, 2) must always be replaced.
Leaks may occur otherwise.

12

Check elastomers of clamps (5) for wear.

If wear is detected:



Replace affected clamp (5).

13

Loosely position clamps (5) on bracket (6).

14

Tighten new high-pressure lines (1, 2) on rail (4) and fuel high-pressure pump (8), while counterholding the fittings on the fuel high-pressure pump (8).

 Union nut, high-pressure line to rail

*BA07.16-N-1003-03A

 Union nut, high-pressure line to fuel high-pressure pump

*BA07.16-N-1004-03A

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

15

Tighten bracket (6) on rail bracket (4).

 Bolt, bracket for high-pressure line to rail bracket

*BA07.16-N-1040-03A

16

Tighten clamp for return lines to bracket (6) with screw (7).

17

Tighten clamps (5) on bracket (6).

 Counterhold clamps (5) when tightening. The clamps (5) must be exactly aligned to the high-pressure lines (1, 2).

 Bolt, high-pressure line clamp to bracket

*BA07.16-N-1007-03A

18

Install resonator box.

Only for engine 471.9

AR13.10-G-5840N

19

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

20

Check area around high-pressure lines (1, 2) and cooling system in terms of leak tightness and stop engine.

 Visual inspection.

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1003-03A

Union nut, high-pressure line to rail

Nm

40

40

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1004-03A

Union nut, high-pressure line to fuel high-pressure pump

Nm

40

40

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1007-03A

Bolt, high-pressure line clamp to bracket

Nm

15

15

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## as of 032691

BA07.16-N-1040-03A

Bolt, bracket for high-pressure line to rail bracket

M6

Nm

15

15

M8

Nm

30

30