Modification notes |
09.10.2018 | Notes regarding safety-relevant component parts added. | AH00.00-Z-0019-01A | |
09.10.2018 | Seal openings on rail (6) and on fuel high-pressure pump (1) with protective covers, added. | Operation step 19 | |
09.10.2018 | Remove protective covers on rail (6) and on fuel high-pressure pump (1), added. | Operation step 26 |
W07.16-1133-09
1 | Fuel system high pressure pump | 4 | Electrical connector | 7 | Sealing rings | ||
2 | Flange | 5 | Fuel high-pressure line | 8 | Sealing rings | ||
3 | Flange | 6 | Rail |
1 | Fuel system high pressure pump |
6 | Rail |
9 | Fuel return line (rail) |
10 | Check valve |
11 | Banjo bolt |
12 | Screw |
13 | Screw |
14 | Fuel line (metering device) |
15 | Engine wiring harness |
16 | Screw |
W07.16-1134-06
W07.16-1136-09
1 | Fuel system high pressure pump | 20 | Positioning disk | A | Marking | ||
17 | Screw | 21 | Gear | B | Casting edge | ||
18 | Sealing ring | 22 | Bracket | C | Cutout | ||
19 | Sealing ring | 23 | Screw |
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 it with the safety strut. | |
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. | |
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. | |
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. | |
Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | ||
Topical note | Notes on tilting the cab | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Notes on self-locking nuts and bolts | ||
Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | |||
Notes on safety-relevant components | |||
| Remove | ||
1 | Tilt cab. | ||
2 | Remove noise encapsulation. | ||
3 | Remove resonator box. | ||
4 | Clean engine in area of the fuel high-pressure pump (1) and fuel-high-pressure line (5). | ||
5 | Drain off fuel from fuel filter module. | ||
Fuel filter cover to fuel filter module | |||
6 | Attach the cranking device. | ||
Bolt, turning device to flywheel housing | |||
Turning device | |||
7 | Position engine at TDC on cylinder 1 and lock in place. | ||
Turning device | |||
Drift | |||
8 | Remove fuel high-pressure line (5) from the fuel high-pressure pump (1) to rail (6). | ||
9 | Disconnect electrical connector (4) from quantity control valve. | ||
10 | Remove flange (2) from fuel high-pressure pump (1). | ||
11 | Remove flange (3) from fuel high-pressure pump (1). | ||
12 | Remove fuel return line (9) from rail (6). | Allow escaping fuel to drain into a suitable container. | |
Ring wrench | |||
13 | Remove screw/bolt (12) from fuel return line (9). | ||
14 | Remove banjo bolt (11) from check valve (10). | Counterhold check valve (10). | |
15 | Remove screws/bolts (13, 16) from fuel line (14). | Push engine wiring harness (15) for screw/bolt (16) to the side. | |
16 | Remove fuel high-pressure pump (1) from bracket (22). | ||
17 | Remove the screws/bolts (17) and remove the fuel high-pressure pump (1). | ||
18 | Remove the sealing rings (18, 19) from the fuel high-pressure pump (1). | ||
19 | Seal openings on rail (6) and on fuel high-pressure pump (1) with protective covers. | | |
Set of protective covers | |||
| Check | ||
20 | Check gear (21) of the fuel high-pressure pump (1) for damage. | If the gear (21) is damaged, | |
| |||
replace gear (21). | |||
21 | Check counter gear of the gear (21) for damage. | Only where gear (21) is damaged. | |
To check, remove drift at flywheel housing and turn engine using turning device by 2 full revolutions. | |||
If the counter gear of the gear (21) is damaged, | |||
| |||
replace counter gear of the gear (21). | |||
22 | Position engine at TDC on cylinder 1 and lock in place. | Only where gear (21) is damaged. | |
| |||
Drift | |||
23 | Remove screws/bolts (23). | Only when replacing the fuel high-pressure pump (1). | |
24 | Clean the sealing surfaces and oil the holes on the fuel high-pressure pump (1) and timing case. | ||
| Install | ||
25 | Screw in screws/bolts (23). | Only when replacing the fuel high-pressure pump (1). | |
Screw/bolt, positioning disk/driver to fuel system high-pressure pump drive wheel | |||
26 | Remove protective covers on rail (6) and on fuel high-pressure pump (1). | | |
Set of protective covers | |||
27 | Attach new sealing rings (18, 19) to the fuel high-pressure pump (1). | ||
28 | Install fuel high-pressure pump(1). | ||
| |||
29 | Fit the screws/bolts (17). | ||
30 | Tighten fuel high-pressure pump (1) on bracket (22). | Screw/bolt, high-pressure fuel pump to bracket | |
31 | Tighten bolts (17). | Screw/bolt, high-pressure fuel pump to timing case | |
32 | Position fuel return line (9) on rail (6). | Do not tighten fuel return line (9) yet. | |
Ring wrench | |||
33 | Tighten banjo bolt (11) on check valve (10). | Install new sealing rings. | |
Banjo bolt for rail return line to check valve | |||
34 | Tighten screw/bolt (12) on fuel return line (9). | Bracket, rail return line to charge air housing | |
35 | Tighten screws/bolts (13, 16) on the fuel line (14). | Push engine wiring harness (15) for screw/bolt (16) to the side. | |
Bracket, fuel line for metering unit | |||
36 | Attach flange (3) to fuel high-pressure pump (1). | Replace sealing rings(8). | |
Flange, low-pressure fuel lines to fuel pump | |||
37 | Attach flange (2) to fuel high-pressure pump (1). | Replace sealing rings (7). | |
Flange, low pressure fuel lines to fuel system high pressure pump | |||
38 | Connect electrical connector (4) to quantity control valve. | ||
39 | Install new fuel high-pressure line (5) from the fuel high-pressure pump (1) to rail (6). | ||
40 | Tighten fuel return line (9) on rail (6). | Union nut, return flow fuel line to rail | |
41 | Remove the cranking device from the timing case. | ||
Bolt, frame sections to frame | |||
42 | Pull out the drift from the timing case. | ||
43 | Install the crankshaft position sensor and tighten the screw/bolt. | Replace O-ring on crankshaft position sensor. | |
Bolt, crankshaft position sensor to flywheel housing | |||
44 | Install resonator box. | ||
45 | Fill fuel low-pressure circuit on engine. | ||
46 | Connect diagnostic system, start XENTRY and perform quick test. | Only when replacing the fuel high-pressure pump (1). | |
47 | Reset "adaptation area for quantity control valve". | Only when replacing the fuel high-pressure pump (1). | |
The process is completely menu-assisted under: | |||
48 | End XENTRY and remove the diagnostic system. | Only when replacing the fuel high-pressure pump (1). | |
49 | Perform engine test run. | Allow the engine to run at a higher engine speed. | |
If engine fails to start or only runs for a brief period, | |||
| |||
refill low-pressure fuel circuit. | |||
50 | Check the engine for leak tightness in the area around the fuel high-pressure pump (1). | Visual inspection. | |
51 | Install soundproofing. | ||
52 | Tilt back cab. |
936 589 00 15 00
Drift
904 589 04 63 00
Turning device
936 589 06 91 00
Set of protective covers
000 589 07 03 00
Ring wrench
Referenced documents
- ah0000n000101a Notes on self-locking nuts and bolts
- ah0000n500001h Notes on avoiding damage through contamination and foreign objects
- ah0000p001501cw Note on calculation of tightening torque when using insertion or socket tools with various effective lengths
- ah0000p002001a Notes on threaded connections fastened using a tightening angle-based tightening process
- ah0000z001901a Notes on safety-relevant components
- ah6080n000301a Notes on tilting the cab
- ar0330w160003na Attach/detach cranking/blocking device for engine
- ar0510w4660na Remove/install gearwheel drive
- ar0703w146003na Drain fuel at fuel filter module
- ar0716w1004na Remove/install high-pressure line to rail
- ar0716w100501md
- ar0716w100501md Install high-pressure fuel pump
- ar0716w100502md Set engine to TDC of cylinder 1 and block
- ar0716w1006na Remove/install drive gear of fuel system high-pressure pump
- ar0716w1007na Fill fuel low-pressure circuit on engine
- ar1310w5840nb Remove/install compressor resonator
- as0000z000501a 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.
- as0716z000101b Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure
- as4700z000101a 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.
- as6080z000101a Risk of injury caused by body parts being pinched or crushed as cab is tilted