Remove/install high-pressure line to rail · ar0716w1004ha · Mercedes-Benz WIS

AR07.16-W-1004HA

Remove/install high-pressure line to rail

15.01.2019

Engine	470.9 in model 963, 964
Engine	471.9## ## as of 032691 in model 963, 964
Engine	473.9 in model 963, 964

Modification notes

05.12.2018	Reference to "Remove high-pressure line to rail" added.	Operation step 7	AR07.16-W-1004-01H
09.10.2018	Notes regarding safety-relevant component parts added.		AH00.00-Z-0019-01A
09.10.2018	Remove protective covers from the rail (4) and from the fuel system high pressure pump (8), added.	Operation step 13

Remove/install high-pressure line to rail

Shown on engine 470.9

1	High pressure pipe
2	High pressure pipe
3	Vibration damper
4	Rail
5	Clip
6	Bracket
7	Screw
8	Fuel high-pressure pump
A	Angle (approx.15°)

W07.16-1128-06

Shown on engine 471.9. as of engine end number 032691

1	High pressure pipe
2	High pressure pipe
3	Vibration damper
4	Rail
5	Clip
6	Bracket
7	Screw
8	Fuel high-pressure pump
A	Angle (approx.15°)

W07.16-1183-06

 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
 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
 Warning	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
 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 it with the safety strut.	AS60.80-Z-0001-01A
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-N-5000-01H
Topical note	Notes on coolant		AH20.00-N-2080-01A
Topical note	Notes on tilting the cab		AH60.80-N-0003-01A
	Notes on compressed air connection systems		AH00.18-N-0001-01A
	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	Tilt cab.
2	Remove noise encapsulation.
3	Drain coolant at expansion reservoir.	Only for vehicles with engine 470.9, 471.9 and code F1P(S-cab) or code F1Q(M (medium-length) cab) and rear expansion reservoir. In a case of poor accessibility to the high-pressure lines (1, 2).
			AR20.00-W-1142-01H
		 Clamp	*000589403700
		 Clamp	*000589543700
4	Remove rear cab carrier.	Only for vehicles with code F1P(S-cab) or code F1Q(M (medium-length) cab) In a case of poor accessibility to the high-pressure lines (1, 2).
			AR60.80-W-0075-01HB
		Lubricant, rubber assembly 1 l	*BR00.45-Z-1010-06A
		 Bolt, rear cab support mounting console to vehicle frame	*BA60.80-N-1025-01B
5	Clean engine in area of high-pressure lines (1, 2).
6	Remove resonator box.	Only for engine 471.9, 473.9.
			AR13.10-W-5840HA
7	Remove high-pressure lines (1, 2) to rail (4).		AR07.16-W-1004-01H
		 Comply with the removal sequence. Otherwise, contamination may damage the diesel injection system.
		 Ring wrench	*000589070300
		 Box wrench socket	*314589010300
		 Set of protective covers	*470589279100
8	Release screw (7).
9	Loosen the bracket (6) on rail (4).
10	Remove vibration dampers (3) from high-pressure lines (1, 2).
	Install
11	Check vibration dampers (3) for wear.	If wear is identifiable,
		
		replace the appropriate vibration damper (3).
12	Attach vibration dampers (3) to the new high-pressure lines (1, 2).	 In doing so maintain the angle (A) at about 15°.
13	Remove protective covers from the rail (4) and from the fuel system high pressure pump (8).	 Do not reuse the  protective covers. In the event of reuse, soiling may damage the diesel injection system.
		 Set of protective covers	*470589279100
14	Loosely position new high-pressure lines (1, 2) on rail (4) and on fuel high-pressure pump (8).	 Always replace removed high-pressure lines (1, 2). Leaks can occur otherwise.
15	Check elastomers of clamps (5) for wear.	If wear is identifiable,
		
		replace the corresponding clamp (5).
16	Loosely place clamps (5) on bracket (6).
17	Tighten new high-pressure lines (1, 2) on rail (4) and fuel high-pressure pump (8), while counterholding the fittings on the fuel high-pressure pump (8).	 Union nut, high-pressure line to fuel high-pressure pump	*BA07.16-N-1004-03A
		 Union nut, high-pressure line to rail	*BA07.16-N-1003-03A
		 Box wrench socket	*314589010300
		 Ring wrench	*000589070300
18	Tighten bracket (6) on rail (4).	 Bolt, bracket for high-pressure line to rail bracket	*BA07.16-N-1040-03A
19	Fasten clamp for the return lines with screw/bolt (7) on bracket (6).
20	Tighten clamps (5) on bracket (6).	 Counterhold clamps (5) when tightening. The clamps (5) must be exactly aligned to the high-pressure lines (1, 2).
		 Bolt, high-pressure line clamp to bracket	*BA07.16-N-1007-03A
21	Install resonator box.	Only for engine 471.9, 473.9.
			AR13.10-W-5840HA
22	Install cab carrier at the rear.	Only for vehicles with code F1P(S-cab) or code F1Q(M (medium-length) cab) In a case of poor accessibility to the high-pressure lines (1, 2).
			AR60.80-W-0075-01HB
		 Bolt, rear cab support mounting console to vehicle frame	*BA60.80-N-1025-01B
		Lubricant, rubber assembly 1 l	*BR00.45-Z-1010-06A
23	Pour in coolant at expansion reservoir.	Only for vehicles with engine 470.9, 471.9 and code F1P(S-cab) or code F1Q(M (medium-length) cab) and rear expansion reservoir. In a case of poor accessibility to the high-pressure lines (1, 2).
			AR20.00-W-1142-01H
		 Coolant	*BF20.00-N-1001-01M
		Lubricant, rubber assembly 1 l	*BR00.45-Z-1010-06A
24	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
25	Check area around the high-pressure lines (1, 2) and the cooling system for leak tightness.	 Visual inspection.
26	Install soundproofing.
27	Tilt back cab.