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 (1) with protective covers, added. | Operation step 24 | |
09.10.2018 | Remove protective covers on rail (4) and on fuel high-pressure pump (1), added. | Operation step 31 |
W07.16-1174-09
1 | Fuel system high pressure pump | 4 | Rail | 7 | Electrical connector | ||
2 | Fuel high-pressure line | 5 | Low pressure fuel lines | 8 | Fuel filter module | ||
3 | Electrical connector | 6 | Electrical connector | R17 | Fuel preheating system heating element |
4 | Rail |
8 | Fuel filter module |
9 | Fuel line |
10 | Overflow valve |
11 | Fuel line |
12 | Fuel return line |
12.1 | Screw |
13 | Screw |
14 | Banjo bolt |
15 | Check valve |
W07.16-1176-06
W07.16-1177-09
1 | Fuel system high pressure pump | 19 | Sealing ring | Pfeil A | Marking | ||
16 | Bracket | 20 | Gear | Pfeil B | Casting edge | ||
17 | Bolts | 21 | Positioning disk | Pfeil C | Cutout | ||
18 | Sealing ring | 23 | Screw |
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. | |
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. | |
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. | |
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. | |
Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | ||
Topical note | Notes on self-locking nuts and bolts | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Notes on tilting the cab | ||
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 the engine in the area of fuel high-pressure pump (1) and fuel high-pressure line (2). | ||
5 | Remove engine management (MCM) control unit (A4). | ||
6 | Bind the electrical connector (3) and engine wiring harness to the side. | ||
7 | Drain the fuel at the fuel filter module (8). | ||
Fuel filter cover to fuel filter module | |||
8 | Attach the cranking device. | ||
Bolt, turning device to flywheel housing | |||
Turning device | |||
9 | Position engine at TDC on cylinder 1 and lock in place. | ||
Drift | |||
Turning device | |||
10 | Remove fuel high-pressure line (2) from the fuel high-pressure pump (1) at rail (4). | ||
11 | Remove the low-pressure fuel lines (5). | ||
12 | Disconnect the electrical connector (6) from the quantity control valve. | ||
13 | Disconnect electrical connector (7) for fuel preheating heating element (R17) at fuel filter module (8). | Only on vehicles with code M8Z (Fuel preheating). | |
14 | Remove the fuel line (9). | Counterhold when releasing the banjo bolt on overflow valve (10). | |
15 | Remove the fuel line (11). | ||
16 | Remove the fuel return line (12) from the rail (4). | Allow escaping fuel to drain into a suitable container. | |
Ring wrench | |||
17 | Remove the banjo bolt (14) from the check valve (15). | Counterhold check valve (15). | |
18 | Remove the screw/bolt (12.1) from the bracket of the fuel return line (12). | ||
19 | Remove the screw/bolt (13) from the fuel filter module (8) and remove the fuel return line (12). | ||
20 | Remove the fuel high-pressure pump (1) from the bracket (16). | ||
21 | Remove the compressed air line from the compressor. | To improve accessibility of the lower screw/bolt (17). | |
22 | Remove the screws/bolts (17) and remove the fuel high-pressure pump (1). | ||
23 | Remove the sealing rings (18, 19) from the fuel high-pressure pump (1). | ||
24 | Seal openings on rail (4) and on fuel high-pressure pump (1) with protective covers. | | |
Set of protective covers | |||
| Check | ||
25 | Check the gear (20) of the fuel high-pressure pump (1) for damage. | If the gear (20) is damaged, | |
| |||
replace the gear (20). | |||
26 | Check counter gear of the gear (20) for damage. | Only where gear (20) 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 (20) is damaged, | |||
| |||
replace the counter gear of the gear (20). | |||
27 | Position engine at TDC on cylinder 1 and lock in place. | Only where gear (20) is damaged. | |
| |||
28 | Remove screws/bolts (23). | Only when replacing the fuel high-pressure pump (1). | |
29 | Clean the sealing surfaces and oil the holes on the fuel high-pressure pump (1) and timing case. | ||
| Install | ||
30 | 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 | |||
31 | Remove protective covers on rail (4) and on fuel high-pressure pump (1). | | |
Set of protective covers | |||
32 | Attach new sealing rings (18, 19) to the fuel high-pressure pump (1). | ||
33 | Install fuel high-pressure pump(1). | ||
| |||
34 | Fit the screws/bolts (17). | ||
35 | Attach the fuel high-pressure pump (1) to the bracket (16). | Screw/bolt, high-pressure fuel pump to bracket | |
36 | Tighten bolts (17). | Screw/bolt, high-pressure fuel pump to timing case | |
37 | Attach the compressed air line to the compressor. | Only when replacing the compressed-air line of the compressor. | |
Union nut, air line to fitting for compressor | |||
38 | Fit the fuel return line (12) to the rail (4). | Do not tighten down fuel return line (12) yet. | |
Ring wrench | |||
39 | Tighten the banjo bolt (14) on the check valve (15). | Install new sealing rings. | |
Banjo bolt for rail return line to check valve | |||
40 | Attach the fuel return line (12) to the fuel filter module (8) using screw/bolt (13). | Replace sealing ring on flange. | |
Screw/bolt, fuel return line to fuel filter module | |||
41 | Tighten the screw/bolt (12.1) on the bracket of the fuel return line (12). | Bracket, rail return line to charge air housing | |
42 | Install the fuel line (11). | Install new sealing rings. | |
Overflow valve with fuel line on diesel fuel metering device | |||
Banjo bolt, fuel feed line for metering device | |||
43 | Install the fuel line (9). | Install new sealing rings. | |
Banjo bolt, fuel line to diesel fuel metering device overflow valve | |||
Bracket, fuel line for metering unit | |||
44 | Connect the electrical connector (7) to fuel preheating heating element (R17). | Only on vehicles with code M8Z (Fuel preheating). | |
45 | Connect the electrical connector (6) to the quantity control valve. | ||
46 | Install the low-pressure fuel lines (5). | Replace sealing rings on the flanges. | |
Flange, low-pressure fuel lines to fuel filter module | |||
Flange, low pressure fuel lines to fuel system high pressure pump | |||
Flange, low-pressure fuel lines to fuel pump | |||
47 | Install new fuel high-pressure line (2) from the fuel high-pressure pump (1) on rail (4). | ||
48 | Tighten fuel return line (12) on rail (4). | Union nut, return flow fuel line to rail | |
49 | Remove the cranking device from the timing case. | ||
Bolt, frame sections to frame | |||
50 | Pull out the drift from the timing case. | ||
51 | Install the crankshaft position sensor and tighten the screw/bolt. | Replace O-ring on crankshaft position sensor. | |
Bolt, crankshaft position sensor to flywheel housing | |||
52 | Install engine management (MCM) control unit (A4) and position engine wiring harness. | ||
53 | Install resonator box. | ||
54 | Fill fuel low-pressure circuit on engine. | ||
55 | Connect diagnostic system, start XENTRY and perform quick test. | Only when replacing the fuel high-pressure pump (1). | |
56 | Reset adaptation area for quantity control valve. | Only when replacing the fuel high-pressure pump (1). | |
The process is completely menu-assisted under: | |||
57 | End XENTRY and remove the diagnostic system. | Only when replacing the fuel high-pressure pump (1). | |
58 | 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. | |||
59 | Check the engine for leak tightness in the area around the fuel high-pressure pump (1). | Visual inspection. | |
60 | Install soundproofing. | ||
61 | 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
- ar0708w7013na Remove/install engine management control unit (MCM)
- 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
- ar1310w5840na 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