Remove/install high-pressure line to fuel injector

AR07.16-G-1003N

Remove/install high-pressure line to fuel injector

08.10.2018

Engine

470.9, 471.9 in model 800.110/112

Modification notes

04.10.2018

Work procedure completely revised.

Shown on engine 470.9

1

High-pressure lines

3

Screw

5

Fuel return line

2

Rail

4

Seal

6

Bracket

 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 avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

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/install

1

Switch off ignition.

2

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

3

Remove compressor resonator box.

Only when removing high-pressure line (1) from cylinder 5 and 6.

Only for engine 471.9

AR13.10-G-5840N

4

Remove high-pressure lines from fuel high-pressure pump to rail (2).

Only when removing high-pressure line (1) from cylinder 5 and 6.

Engine 470.9, 471.9 as of engine end number 032691

AR07.16-G-1004NA

Engine 471.9 up to engine end number 032690

AR07.16-G-1004N

5

Remove fuel return line (5) from rail (2).

Only when removing high-pressure line (1) from cylinder 5 and 6.

 Installation: Install new sealing rings.

 Engine 470.9, 471.9.Banjo bolt, fuel line to rail (pressure limiting valve return)

*BA07.16-N-1024-03A

6

Loosen screws (3) on the corresponding seal (4).

 Engine 470.9, 471.9.Bolt, high-pressure line cover to camshaft case

*BA07.16-N-1005-03A

7

Remove high-pressure lines (1).

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

 Installation: Position high-pressure line (1); tighten first on fuel injector and then on rail (2).

 Engine 470.9, 471.9.Connection fitting, high-pressure line to cylinder fuel injector

*BA07.16-N-1002-03A

 Engine 470.9, 471.9.Union nut, high-pressure line to rail

*BA07.16-N-1003-03A

 Ring wrench

*000589070300

 Open end wrench attachment, 19_mm

*000589109919

 Torque wrench

*001589662100

 Box wrench socket

*314589010300

8

Remove screws (3) and remove seal (4).

Only if seal (4) is leaky.

 Installation: Coat new seal (4) on the inside with engine oil. Do not tighten screws (3) yet.

9.1

Seal openings on rail (2) with protective covers.

If during continued work the fuel high-pressure circuit should be checked for leaktightness using the diagnostic system.

 Engine 470.9, 471.9.Stop plug to rail

*BA07.16-N-1032-03A

 Open end wrench attachment, 19_mm

*000589109919

 Torque wrench

*001589662100

 Stop plug

*470589129100

9.2

Seal openings on the rail (2) with dust caps.

If during continued work no leak test of the high-pressure fuel circuit takes place.


Do not reuse the  protective covers.
If they are reused, the system may be damaged due to soiling.

 Set of protective covers

*470589279100

10

Install in the reverse order.

11

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

12

Check area of high-pressure lines (1) on rail (2) and seals (4) in terms of leak tightness.

 Visual inspection.

13

Switch off engine.

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## up to 032690

BA07.16-N-1002-03A

Connection fitting, high-pressure line to cylinder fuel injector

Nm

40

40

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## as of 032691

BA07.16-N-1002-03A

Connection fitting, high-pressure line to cylinder fuel injector

Nm

40

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## up to 032690

BA07.16-N-1003-03A

Union nut, high-pressure line to rail

Nm

40

40

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## as of 032691

BA07.16-N-1003-03A

Union nut, high-pressure line to rail

Nm

40

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## up to 032690

BA07.16-N-1005-03A

Bolt, high-pressure line cover to camshaft case

Nm

15

15

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## as of 032691

BA07.16-N-1005-03A

Bolt, high-pressure line cover to camshaft case

Nm

15

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## up to 032690

BA07.16-N-1024-03A

Banjo bolt, fuel line to rail (pressure limiting valve return)

M14x1.5

Nm

30

30

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## as of 032691

BA07.16-N-1024-03A

Banjo bolt, fuel line to rail (pressure limiting valve return)

M14x1.5

Nm

30

 Common rail diesel injection system

Number

Designation

Engine 470.9

Engine 471.9## ## up to 032690

BA07.16-N-1032-03A

Stop plug to rail

Nm

40

40

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## as of 032691

BA07.16-N-1032-03A

Stop plug to rail

Nm

40