Remove/install MR/PLD injection lines

AR07.15-G-9235B

Remove/install MR/PLD injection lines

11.10.2018

Engine

900.915/916/920/921, 902.923/924/935, 904.927/928/952/953, 906.935/955, 924.916/923/931, 926.969

1

Injection line

2

Pressure screw

3

Engine cover

4

Air intake line

1

Injection lines

2

Pressure screw

5

Vibration damper (only for engine 900, 902.923/924, 924.923/931)

Only for engine 900, 902.923/924, 924.923/931

1

Injection line

5

Vibration damper

A

Adjustment dimension

 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 self-locking nuts and bolts

AH00.00-N-0001-01A

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

AH00.00-P-0015-01CW



Remove

1.1

Tilt cab to repair position.

Model 405, model 437.42/43

AR60.80-G-0005B

1.2

Open hood.

Model 437.46

 See information from body manufacturer.

2

Remove engine cover above the engine.

Only for engine 900.915/916 in model 405.05

AR01.10-G-2405E

3

Remove air intake line (4) from the engine cover (3).

4

Remove engine cover (3).

5

Remove mounting support for refrigerant compressor.

Only for engine 924.916 in model 437.465 as of 01.04.17 with code M25 (refrigerant compressor reinforced), engine 924.916 in model 437.465 up to 31.03.17 with code M46 (additional alternator + air conditioner compressor, reinforced), engine 926.969 in model 437.467 with code M25 (refrigerant compressor, reinforced)
Only when removing the injection line (1) of the first cylinder.

Engine 924.916 in model 437.465

AR83.55-G-5360CM

Engine 926.969 in model 437.467

AR83.55-G-5410F

6

Remove injection lines (1).


Do not bend injection lines (1).
Otherwise, the coating in the injection line (1) will be damaged and engine damage may occur as a result.

 Ring wrench

*000589070300

 Box wrench bit

*000589680300

7

Seal bores on the connection fittings and on the unit pumps with the stop plugs.

 Plug

*963589019100



Check

8

Check injection lines (1) for damage.

 Visual inspection.

If problems exist,



replace affected injection lines (1).

9

Check vibration dampers (5) on the injection lines (1) for tight seating and check their installation position.

Only for engine 900.915/916/920/921, 902.923/924, 924.923/931

 The installation position is correct if the adjustment dimension (A) of the vibration damper (5) is correct and the long side of the bracket is flush with the injection line (1).

If problems exist,



align the vibration damper (5) or replace if it is not seated tightly.

Adjustment dimension of vibration damper on injection line

*BE07.15-N-1001-01C

 Vibration damper on injection line

*BA07.15-N-1010-01E

10

Check pressure screws (2) of the connection fittings for tight seating.

 Thrust bolt, connection fitting to cylinder head

*BA07.15-N-1005-01E



Install

11

Install injection lines (1).


Do not bend injection lines (1).
Otherwise, the coating in the injection line (1) will be damaged and engine damage may occur as a result.

 Injection line to connection fitting and unit pump

*BA07.15-N-1004-01E

 Ring wrench

*000589070300

 Box wrench bit

*000589680300

12

Start engine and run.

13

Check injection lines (1) and threaded connections for leak tightness.

If problems exist,



replace leaky injection lines (1).

14

Switch off engine.

15

Install mounting support für for refrigerant compressor.

Only for engine 924.916 in model 437.465 as of 01.04.17 with code M25 (refrigerant compressor reinforced), engine 924.916 in model 437.465 up to 31.03.17 with code M46 (additional alternator + air conditioner compressor, reinforced), engine 926.969 in model 437.467 with code M25 (refrigerant compressor, reinforced)
Only when removing the injection line (1) of the first cylinder.

Engine 924.916 in model 437.465

AR83.55-G-5360CM

Engine 926.969 in model 437.467

AR83.55-G-5410F

16

Install engine cover (3).

17

Attach air intake line (4) to the engine cover (3).

18

Install engine cover above the engine.

Only for engine 900.915/916 in model 405.05

AR01.10-G-2405E

19.1

Tilt back cab.

Model 405, model 437.42/43

AR60.80-G-0005B

19.2

Close hood.

Model 437.46

 See information from body manufacturer.

Check values for injection line (PLD)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.93/95, 924.91/92/93, 926.96

BE07.15-N-1001-01C

Adjustment dimension of vibration damper on injection line

mm

7,4...8,4

 Diesel injection system with unit pumps (MR/PLD)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA07.15-N-1004-01E

Injection line to connection fitting and unit pump

Nm

35

 Diesel injection system with unit pumps (MR/PLD)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA07.15-N-1005-01E

Thrust bolt, connection fitting to cylinder head

Nm

45

 Diesel injection system with unit pumps (MR/PLD)

Number

Designation

Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96

BA07.15-N-1010-01E

Vibration damper on injection line

Nm

4