Remove/install high-pressure line to fuel injector · ar0716w1003h · Mercedes-Benz WIS

AR07.16-W-1003H

Remove/install high-pressure line to fuel injector

15.10.2018

Engine	470.9 in model 963, 964
Engine	471.9 in model 963, 964
Engine	473.9 in model 963, 964

Modification notes

09.10.2018	Notes regarding safety-relevant components, added.		AH00.00-Z-0019-01A
09.10.2018	Protective cover special tool, added.	Step 13.2

Remove/install high-pressure line to fuel injector

W07.16-1182-08

Shown on engine 470.9

1	High-pressure lines	4	Seal
2	Rail	5	Fuel return line
3	Screw	6	Bracket

 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
 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.	AS60.80-Z-0001-01A
 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
Topical note	Notes on tilting the cab		AH60.80-N-0003-01A
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	Tilt cab.	 Installation: Only tilt back cab after the leak test.
3	Remove soundproofing.	 Installation: Only install soundproofing after the leak test.
4	Clean engine in the area of the high-pressure lines (1).
5	Remove compressor resonator box.	Only for engine 471.9, 473.9. Only when removing high-pressure line (1) from cylinder 5 and 6.
			AR13.10-W-5840HA
6	Remove high-pressure lines from fuel high-pressure pump to rail (2)	Only on engine 470.9, 471.9 Only when removing high-pressure line (1) from cylinder 5 and 6.
		Engine 471.9 up to engine end number 032690	AR07.16-W-1004H
		Engine 470.9, 471.9 as of engine end number 032691	AR07.16-W-1004HA
7	Remove high-pressure lines from fuel high-pressure pump to rail (2)	Only for engine 473.9. Only when removing high-pressure line (1) from 6th cylinder.
			AR07.16-W-1004HA
8	Remove the fuel return line (5) from the rail (2).	Only with engine 470.9, 471.9. Only when removing high-pressure line (1) from cylinder 5 and 6.
		 Installation: Install new sealing rings.
		 Engine 470.9, 471.9Banjo bolt, fuel line to rail (pressure limiting valve return)	*BA07.16-N-1024-03A
9	Remove the fuel return line (5) from the rail (2).	Only for engine 473.9. Only when removing high-pressure line from 6th cylinder.
		 Installation: Install new sealing rings.
		 Banjo bolt, fuel line to rail (pressure limiting valve return)	*BA07.16-N-1024-03A
10	Release screw/bolts (3) on seal (4).	 Engine 470.9, 471.9, 473.9Bolt, high-pressure line cover to camshaft case	*BA07.16-N-1005-03A
11	Remove high-pressure lines (1).	 Always replace removed high-pressure lines (1). Leaks can occur otherwise.
		 Installation: Position high-pressure line (1), first tighten on injection nozzle and then on the rail (2).
		 Engine 470.9, 471.9, 473.9Connection fitting, high-pressure line to cylinder fuel injector	*BA07.16-N-1002-03A
		 Engine 470.9, 471.9, 473.9Union nut, high-pressure line to rail	*BA07.16-N-1003-03A
		 Ring wrench	*000589070300
		 Box wrench socket	*314589010300
12	Remove screw/bolts (3) and take off seal (4).	Only if seal (4) is leaky.
		 Installation: Coat inside of seal (4) with engine oil. Do not tighten screws (3) yet.
13.1	Seal openings on the rail (2) with stop plugs.	If during continued work a leak test of the high-pressure fuel circuit takes place.
		 Engine 470.9, 471.9, 473.9Stop plug to rail	*BA07.16-N-1032-03A
		 Stop plug	*470589129100
13.2	Seal openings on the rail (2) with protective covers.	If during continued work no leak test of the high-pressure fuel circuit takes place.
		 Do not re-use the  protective covers. In the event of re-use, contamination can damage the diesel injection system.
		 Set of protective covers	*470589279100
14	Install in the reverse order
15	Perform engine test run.	 Allow the engine to run at a higher engine speed.
		If the engine fails to start or only runs for a brief period,
		
		refill low-pressure fuel circuit.
			AR07.16-W-1007H
16	Check area of the high-pressure lines (1) on the rail (2) and seals (4) for leak tightness.	 Visual inspection.