Remove/install MR/PLD injection lines

AR07.15-G-9235DD

Remove/install MR/PLD injection lines

21.08.2019

Engine

900.91/92 in model 000.001

Engine

902.91/93 in model 000.001

Engine

904.94/95/96/97 in model 000.001

Engine

906.93/94/95/96/98/99 in model 000.001

Engine

924.91/93/94 in model 000.001

Engine

925.9 in model 000.001

Engine

926.91/92/93/95/97/98 in model 000.001

1

Injection line

2

Pressure screw

3

Engine cover

4

Compressor air intake duct

1

Injection line

2

Pressure screw

5

Vibration damper (only for BlueTEC)

Only for BlueTEC

1

Injection line

5

Vibration damper

A

Distance

 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

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

AH00.00-P-0015-01CW



Remove

1

Remove clamp (arrow) for compressor air intake line (4) from engine cover (3).

Only when removing the injection lines (1) for the 3rd to 6th cylinder and if the engine cover (3) has been installed.

2

Remove engine cover (3).

Only if the engine cover (3) has been installed.

3

Remove injection lines (1).


Do not bend injection lines (1).
The coating in the injection line (1) can be destroyed otherwise.

 Ring wrench

*000589070300

 Box wrench bit

*000589680300

4

Close off holes on connection fitting and the unit pump.



Check

5

Check injection lines (1).

 Visual inspection.

If necessary,



Replace injection lines (1).

6

Check the tightness and installation position of the vibration damper (5) on the injection lines (1).

Only for BlueTEC.

 Align the vibration damper (5) with the injection lines (1); to do so, turn the vibration damper (5) until the long side of the bracket stands aligned with the injection pipe.
Observe gap (A) to bending.

Adjustment dimension of vibration damper on injection line

*BE07.15-N-1001-01B

 Vibration damper on injection line

*BA07.15-N-1010-01D

7

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

 Thrust bolt, pressure pipe connection to cylinder head

*BA07.15-N-1005-01D



Install

8

Install injection lines (1).

 Injection line to connection fitting and unit pump (MR/PLD)

*BA07.15-N-1004-01D

 Ring wrench

*000589070300

 Box wrench bit

*000589680300



Check

9

Start the engine and let it run at varying engine speeds.

 See information from body manufacturer.
Start engine with starter for max. 90 s.
The fuel system is bled automatically.

If the engine switches off or does not start:



Wait for about  2  minutes before repeating starting attempt.

10

Check area of injection line (1) for leakage, then shut off the engine.

If a leak is present,



Also replace corresponding injection line (1) if necessary.

11

Install engine cover (3).

Only if the engine cover (3) has been removed.

12

Install clamp (arrow) on compressor air intake duct (4) at engine cover (3).

Only if the injection lines (1) for the 3rd to 6th cylinder have been removed and if the engine cover (3) has been installed.

Check values for injection line (PLD)

Number

Designation

Engine 900.92, 902.93, 924.93, 925.9, 926.9 in model 000.001

BE07.15-N-1001-01B

Adjustment dimension of vibration damper on injection line

mm

7,4...8,4

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

Number

Designation

Engine 900.9, 902.9 (except 902.90), 904.9, 906.9 (except 906.90) in model 000.001

Engine 924.9, 925.9, 926.9 in model 000.001

BA07.15-N-1004-01D

Injection line to connection fitting and unit pump (MR/PLD)

Nm

35

35

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

Number

Designation

Engine 900.9, 902.9 (except 902.90), 904.9, 906.9 (except 906.90) in model 000.001

Engine 924.9, 925.9, 926.9 in model 000.001

BA07.15-N-1005-01D

Thrust bolt, pressure pipe connection to cylinder head

Nm

45

45

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

Number

Designation

Engine 900.9, 902.9 (except 902.90), 904.9, 906.9 (except 906.90) in model 000.001

Engine 924.9, 925.9, 926.9 in model 000.001

BA07.15-N-1010-01D

Vibration damper on injection line

Nm

-

4