Remove/install high-pressure line to fuel injector

AR07.16-W-1003NE

Remove/install high-pressure line to fuel injector

18.06.2020

Engine

936.9 in model 956

1

High-pressure line

3

Sealing ring

4

Cylinder head

2

Rail

 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

 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 avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

Topical note

Notes on tilting the cab

AH60.80-N-0003-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW



Remove

1

Switch off ignition.

2

Tilt cab.

3

Remove noise encapsulation near the high-pressure lines (1).

4

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

5

Remove resonator box.

Only when removing the high-pressure line (1) on cylinder 5 or 6.

AR13.10-W-5840NE

6

Remove high-pressure lines (1).

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

7

Remove left charge air pipe with charge air resonator from mixer housing.

Only when installing new sealing ring (3) for cylinder 2.

Vehicles without code M2H (Engine M936G, R6, 7.7 l, 222 kW (302 hp), 1200 Nm)

AR09.41-W-1327NE

8

Remove sealing rings (3) in cylinder head (4).

Only when installing new sealing rings (3).

AR07.16-W-1003-01MD

 Slide hammer puller

*936589033302

 Puller

*936589043300

9.1

Seal openings on the rail (2) with stop plugs.

Only if during continued work a leak test of the high-pressure fuel circuit takes place.

 Stop plug to rail

*BA07.16-N-1005-03B

 Plug

*936589019100

9.2

Seal openings on the rail (2) with protective covers.

Only 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

*936589069100



Install

10.1

Remove protective covers from the rail (2).

Only if during continued work a leak test of the high-pressure fuel circuit took 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

*936589069100

10.2

Remove stop plugs from the rail (2).

Only if during continued work no leak test of the high-pressure fuel circuit took place.

 Plug

*936589019100

11

Install sealing rings (3) in cylinder head (4).

Only when installing new sealing rings (3).

AR07.16-W-1003-01MD

 Stamp in new sealing rings (3) to the end stop in the cylinder head (4).

 Insertion drift

*638589111500

12

Attach left charge air pipe with charge air resonator to mixer housing.

Only when installing new sealing ring (3) for cylinder 2.

Vehicles without code M2H (Engine M936G, R6, 7.7 l, 222 kW (302 hp), 1200 Nm)

AR09.41-W-1327NE

13

Release rail (2) from cylinder head (4).

14

Coat inside of sealing rings (3) with engine oil.

15

Put on new high-pressure lines (1) and apply union nuts.


Always replace removed high-pressure lines (1).
Leaks can occur otherwise.

 Put on fuel high-pressure lines (1), first tighten union nuts on rail (2), then on fuel injector by hand but do not tighten it down yet.

16

Tighten rail (2) on cylinder head (4).

 Screw/bolt, rail to cylinder head

*BA07.16-N-1007-03B

17

Tighten high-pressure lines (1).


Tighten high-pressure lines (1) firstly on the rail (2) and then on the fuel injectors.
Leaks can occur otherwise.

 High-pressure line pressure pipe connection on cylinder fuel injector

*BA07.16-N-1003-03B

 Union nut, high-pressure line to rail

*BA07.16-N-1004-03B

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

18

Install resonator box.

Only after removal of the high-pressure line (1) on cylinder 5 or 6.

AR13.10-W-5840NE

19

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-1007MD

20

Check area of the high-pressure lines (1) on the rail (2) for leak tightness.

 Visual check.

21

Install noise encapsulation.

22

Tilt back cab.

 Common rail diesel injection system

Number

Designation

Engine 936.9

BA07.16-N-1003-03B

High-pressure line pressure pipe connection on cylinder fuel injector

M161.5

Nm

45

 Common rail diesel injection system

Number

Designation

Engine 936.9

BA07.16-N-1004-03B

Union nut, high-pressure line to rail

M201.5

Nm

45

 Common rail diesel injection system

Number

Designation

Engine 936.9

BA07.16-N-1005-03B

Stop plug to rail

Nm

35

 Common rail diesel injection system

Number

Designation

Engine 936.9

BA07.16-N-1007-03B

Screw/bolt, rail to cylinder head

Nm

55