Remove/install MR/PLD injection lines

AR07.15-W-9235G

Remove/install MR/PLD injection lines

31.05.2016

Engine

541.9 in model 930, 932, 933, 934

Engine

542.9 in model 930, 932, 934

Modification notes

16.12.2015

Union nut, injection line to connection fitting/unit pump

BA07.15-N-1004-01B

14.01.2016

Note on calculating tightening torque when using insertion tools with various effective lengths, added.

Operation step 5

AH00.00-P-0015-01CW

07.01.2016

Injection line union nut tightening torque to connection fitting/unit pump, added.

Operation step 5

BA07.15-N-1004-01B

26.02.2016

Thrust bolt, connection fitting to cylinder head

BA07.15-N-1005-01B

Shown on engine 542.9 with code MS5 (BlueTec 5)

1

Injection line

2

Connection fitting

3

Pressure screw

 Danger !

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 with the safety strut.

AS60.80-Z-0001-01A

 Danger !

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 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



Notes on tilting the cab

AH60.80-N-0003-01A



Remove

1

Remove charge air distributor

AR09.41-W-8682A

2

Mark installation position of injection line (1) in relation to corresponding cylinder

3

Remove injection line (1)


The injection line (1) must not be bent.
The coating in the injection line (1) can come off otherwise. This can lead to engine damage.

 Ring wrench

*000589070300



Install

4

Tighten pressure screw (3) on connection fitting (2)

 Thrust bolt, connection fitting to cylinder head

*BA07.15-N-1005-01B

5

Install injection line (1)



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

AH00.00-P-0015-01CW


The injection line (1) must not be bent.
The coating in the injection line (1) can come off otherwise. This can lead to engine damage.

 Note marking. Tighten down rear injection line (1) in the area of the compressor using the 17 mm open end wrench bit.

 Union nut, injection line to connection fitting/unit pump

*BA07.15-N-1004-01B

 Tool kit

*000589109900

 Box wrench bit

*000589680300

6

Install charge air distributor

AR09.41-W-8682A

 Only tilt back cab after the leak test.

7

Start engine and allow to run for about 10 s in neutral then run the engine at varying speeds

 The fuel system is bled automatically.

If engine fails to start or only runs for a brief period



Bleed fuel system.



AP47.00-W-1720-01A

8

Check threaded connections on injection line (1) by means of a visual inspection for leaktightness

 Check injection line (1) on unit pump under the charge air distributor using a mirror.

9

Turn off engine

10

Tilt back cab

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

Number

Designation

Engine 541.9, 542.9

BA07.15-N-1004-01B

Union nut, injection line to connection fitting/unit pump

without code MS7 (BlueTec EEV)

Nm

30

with code MS7 (BlueTec EEV)

Nm

35

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

Number

Designation

Engine 541.9, 542.9

BA07.15-N-1005-01B

Thrust bolt, connection fitting to cylinder head

Nm

45