Remove/install high-pressure line to rail

AR07.16-W-1004MD

Remove/install high-pressure line to rail

15.10.2018

Engine

936.9 in model 963, 964

Modification notes

09.10.2018

Notes regarding safety-relevant component parts added.

AH00.00-Z-0019-01A

09.10.2018

Seal openings on rail (4) and on fuel high-pressure pump (2) with protective covers, added.

Step 9

09.10.2018

Remove protective covers on rail (4) and on fuel high-pressure pump (2), added.

Operation step 10

1

High pressure pipe

3

Screw/bolt

2

Fuel high-pressure pump

4

Rail

 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 injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut.

AS60.80-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

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

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



Remove

1

Switch off ignition.

2

Tilt cab.

3

Remove noise encapsulation.

4

Clean engine in the area of the high-pressure line (1).

5

Remove resonator box.

AR13.10-W-5840MD

6

Loosen union nuts on high-pressure line (1), on rail (4) and on the fuel high-pressure pump (2).

 Ring wrench

*000589070300

7

Loosen screws/bolts (3) on rail (4).

8

Remove the high-pressure line (1).

9

Seal openings on rail (4) and on fuel high-pressure pump (2) with protective covers.


Do not reuse the  protective covers.
In the event of reuse, soiling may damage the diesel injection system.

 Set of protective covers

*936589069100



Install

10

Remove protective covers on rail (4) and on fuel high-pressure pump (2).


Do not reuse the  protective covers.
In the event of reuse, soiling may damage the diesel injection system.

 Set of protective covers

*936589069100

11

Insert new high-pressure line (1) between rail (4) and fuel high-pressure pump (2).


Always replace high-pressure line (1).
Leaks can occur otherwise.

 The sealing cone on the high-pressure line (1) must not impact on the rail (4) or on the fuel high-pressure pump (2).

12

Place union nuts of the high-pressure line (1) on rail (4) and on fuel high-pressure pump (2) by hand.

 Align high-pressure line (1).

13

Tighten screws/bolts (3) on the rail (4).

 Screw/bolt, rail to cylinder head

*BA07.16-N-1007-03B

 Torque wrench

*001589662100

14

Tighten union nuts of high-pressure line (1).

 Union nut, high-pressure line to rail

*BA07.16-N-1004-03B

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

*BA07.16-N-1006-03B

15

Install resonator box.

AR13.10-W-5840MD

16

Perform engine test run.

 Run engine at an increased idle speed.

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



refill low-pressure fuel circuit.

AR07.16-W-1007MD

17

Check area of the high-pressure line (1) for leak tightness.

 Visual inspection.

18

Install soundproofing.

19

Tilt back cab.

 Common rail diesel injection system

Number

Designation

Engine 936.9

BA07.16-N-1004-03B

Union nut, high-pressure line to rail

M201.5

Nm

45

 Common rail diesel injection system

Number

Designation

Engine 936.9

BA07.16-N-1006-03B

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

Nm

45

 Common rail diesel injection system

Number

Designation

Engine 936.9

BA07.16-N-1007-03B

Screw/bolt, rail to cylinder head

Nm

55