Remove/install high-pressure line to rail

AR07.16-G-1004N

Remove/install high-pressure line to rail

14.01.2019

Engine

471.9## ## up to 032690 in model 800.110/112

Modification notes

04.10.2018

Work procedure completely revised.

5

Rail

6

High pressure pipe

7

High pressure pipe

8

Clip

9

Bracket

10

Bracket

11

Clip

12

Vibration damper

13

Fuel system high pressure pump

A

Angle (approx. 15°)

 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 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-N-5000-01H

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

Clean engine in area of high-pressure lines (6, 7).

3

Remove resonator box.

AR13.10-G-5840N

4

Remove bracket (9) on bracket (10).

5

Unscrew high-pressure lines (6, 7) on rail (5) and on fuel high-pressure pump (13).

 Counterhold fitting on fuel system high pressure pump (13).

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

6

Remove bracket (10) on charge-air distributor and take off together with high-pressure lines (6, 7).

 The bracket (10) and the high-pressure lines (6, 7) to the rail must not be reused. They must be replaced together with the clamps (8, 11) and the vibration dampers (12).



Install

7

Attach new vibration dampers (12) to the new high-pressure lines (6, 7).

 Screw vibration dampers (12) onto straight section of high-pressure line after first bend, observing the angle (A) of approx. 15°.

8

Install new high-pressure line (6).

 Union nut, high-pressure line to rail

*BA07.16-N-1003-03A

 Union nut, high-pressure line to fuel high-pressure pump

*BA07.16-N-1004-03A

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

9

Install new bracket (10) on charge-air distributor and on bracket (9).

10

Install new high-pressure line (7).

 Union nut, high-pressure line to rail

*BA07.16-N-1003-03A

 Union nut, high-pressure line to fuel high-pressure pump

*BA07.16-N-1004-03A

 Ring wrench

*000589070300

 Box wrench socket

*314589010300

11

Install new clamps (8, 11) on new bracket (10)

 Bolt, high-pressure line clamp to bracket

*BA07.16-N-1007-03A

12

Install resonator box (1).

AR13.10-G-5840N

13

Start engine and perform an engine test run.

 Allow the engine to run at a higher engine speed.
See information from body manufacturer.

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



Fill fuel low-pressure circuit.

AR07.16-G-1007N

14

Check area around high-pressure lines (6, 7) for leak tightness and switch off engine.

 Visual inspection.

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1003-03A

Union nut, high-pressure line to rail

Nm

40

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1004-03A

Union nut, high-pressure line to fuel high-pressure pump

Nm

40

 Common rail diesel injection system

Number

Designation

Engine 471.9## ## up to 032690

BA07.16-N-1007-03A

Bolt, high-pressure line clamp to bracket

Nm

15