W 21-04-03 Removing and installing the pressure relief valve (Rail

Removing and installing the pressure relief valve (Rail)

● Conventional tools ● Special tools: – Locking plugs/caps – Disassembly tool – Assembly grease 01899368 02992127

01016496 – Safety information / User information – Operating manual

DANGER

Do not carry out work on the fuel system when the engine is running. The fuel system is under high pressure risk of death. Even after the engine shuts down, the fuel pressure may still be up to several 100 bar for a long time. The fuel pressure here does not drop until the fuel system is opened and the fuel can escape to the outside.

ATTENTION

Ensure the utmost cleanliness when performing all work. Remove any paint residue and dirt particles before disassembly. Carefully clean the area around the components concerned. Blow wet parts dry with compressed air. Observe safety regulations and national regulations when working with fuels. Close all connections immediately after opening with new, clean locking plugs/caps. Do not remove locking plugs/caps until immediately before assembling. Collect leaking operating media in suitable vessels and dispose of them according to regulations. Vent the fuel system after doing any work on it - see operating manual. For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

Removing the pressure relief valve

● Unscrew pressure relief valve (1). Collect any escaping fuel and dispose of it according to regulations.

● Visually inspect thread and sealing edge of the pressure relief valve.

● Remove O-ring (1) with disassembly tool.

© 25096-01

© 04965-01

Installing the pressure relief valve

ATTENTION

No foreign matter must get into the rail. Ensure utmost cleanliness. Especially on the thread and sealing surface of the rail. Observe the spare parts documentation. In case of replacement, the rail pressure sensor and the pressure relief valve must be replaced as a pair. Do not twist or overtighten the O-ring. Do not damage the O-ring! ● Clean thread and sealing edge of the pressure relief valve. ● Mount a new O-ring (1). Use a suitable assembly aid. Provide protection for sharp edges.

● Lightly coat the thread and sealing edge of the pressure relief valve with assembly grease.

● Clean thread and sealing area of the rail. ● Screw in pressure relief valve (1). ● Tighten pressure relief valve. 100 Nm

© 05374-02

© 04971-01