Attach/detach test adapter to XENTRY for guided measurement of return quantity of injectors and rail pressure regulating valve

AR07.16-W-0145MD

Attach/detach test adapter to XENTRY for guided measurement of return quantity of injectors and rail pressure regulating valve

10.04.2019

Engine

934.9, 936.9 in model 967

Engine

936.9 in model 956, 963, 964

Shown on engine 936.9

1

Rail

2

Fuel return line

3

Electrical wiring harness

4

Check valve (pressure regulating valve)

5

Fuel high-pressure line

6

Clip

Y634

Pressure regulator valve

Y635

Camshaft positioner solenoid

Y643

Quantity control valve

X603.16

Cylinder head electrical connector

Shown on engine 936.9 in model 963

2

Fuel return line

7.2

Test adapter

7.5

Plug

4

Check valve (pressure regulating valve)

7.3

Plug

8

Banjo bolt

7.1

Banjo bolt

7.4

Test adapter

9

Hose

 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

 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

Notes on safety-relevant components

AH00.00-Z-0019-01A

Attach, remove

1

Open cap of fuel tank and close again

 To remove the fuel pressure.

2

Remove compressor resonator

Engine 936.9 in model 956

AR13.10-W-5840NE

ENGINE 934.9 in MODEL 967

AR13.10-W-5840NA

Engine 936.9 in model 967

AR13.10-W-5840NB

ENGINE 936.9 in MODEL 963, 964

AR13.10-W-5840MD

 Installation: Only install the resonator after performing the leak test.

3

Switch off ignition

4

Disconnect electrical connection on pressure regulating valve (Y634), on quantity control valve (Y643) and on camshaft positioner solenoid (Y635)

Only for engine 936.9.

5

Expose electrical wiring harness (3) on charge air distributor and on cylinder head in the area of the fuel system high pressure pump

6

Disconnect cylinder head electrical connection (X603.16) and remove electrical wiring harness (3) under the fuel high-pressure line (5)

Only for engine 936.9.

7

Remove clamp (6) for fuel return line (2)

8

Remove fuel return line (2) at rail (1)

 Union nut, return flow fuel line to rail

*BA07.16-N-1015-03B

 Ring wrench

*000589070300

 Torque wrench

*001589662100

9

Remove fuel return line (2) on check valve (4)

 Counterhold check valve (4).

 Installation: Replace sealing rings and counterhold check valve (4).

 Banjo bolt for rail return line to check valve

*BA47.25-N-1001-01O

10

Attach test adapter (7.2) with banjo bolt (7.1) and sealing rings on the check valve (4)

 Counterhold check valve (4). The return quantity of the injectors is measured with the test adapter (7.2).

 Banjo bolt for adapter for return flow quantity measurement to check valve

*BA47.25-N-1008-01O

 Adapter

*936589049100

11

Seal fuel return line (2) with banjo bolt (8) and sealing rings and the stop plug (7.5)

 Stop plug to rail return line banjo bolt

*BA47.25-N-1007-01O

 Adapter

*936589049100

12

Close off fuel return line (2) with grommets (7.3)

 Stop plug to rail return line

*BA47.25-N-1006-01O

 Adapter

*936589049100

13

Attach electrical connections to pressure regulating valve (Y634), to quantity control valve (Y643) and to camshaft positioner solenoid (Y635)

Only for engine 936.9.

14

Attach cylinder head electrical connection (X603.16)

Only for engine 936.9.

15

Attach test adapter (7.4) to rail (1)

 The return quantity of the pressure regulating valve (Y634) is measured with the test adapter (7.4).

 Union nut, adapter for return flow quantity measurement to rail

*BA07.16-N-1025-03B

 Adapter

*936589049100

16

Screw on hoses (9) for measurement of the return quantity at the test adapters (7.2, 7.4) and connect respectively to a separate measuring tank

 Test adapter

*470589022100

17

Disassemble in the reverse order

18

Start engine and perform an engine test run

 Allow engine to run at a higher rotational speed.

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



Fill fuel low-pressure circuit on engine.

Model 967

AR07.16-W-1007NA

Model 956, 963, 964

AR07.16-W-1007MD

19

Check area around the fuel return line (2) on rail (1) and check valve (4) for leaktightness

 Visual inspection.

 Common rail diesel injection system

Number

Designation

Engine 934.9

Engine 936.9

BA07.16-N-1015-03B

Union nut, return flow fuel line to rail

Nm

30

30

 Common rail diesel injection system

Number

Designation

Engine 934.9

Engine 936.9

BA07.16-N-1025-03B

Union nut, adapter for return flow quantity measurement to rail

Nm

30

30

 Fuel lines/hoses

Number

Designation

Engine 934.9

Engine 936.9

BA47.25-N-1001-01O

Banjo bolt for rail return line to check valve

Nm

25

25

 Fuel lines/hoses

Number

Designation

Engine 934.9

Engine 936.9

BA47.25-N-1006-01O

Stop plug to rail return line

Nm

30

30

 Fuel lines/hoses

Number

Designation

Engine 934.9

Engine 936.9

BA47.25-N-1007-01O

Stop plug to rail return line banjo bolt

Nm

25

25

 Fuel lines/hoses

Number

Designation

Engine 934.9

Engine 936.9

BA47.25-N-1008-01O

Banjo bolt for adapter for return flow quantity measurement to check valve

Nm

25

25