Remove/install injection lines of common rail direct injection

AR07.16-P-1080MCD

Remove/install injection lines of common rail direct injection

23.04.2019

Engine

660.9 in model 451.3/4

1

Injection line

2

Rail

Y76/1

Cylinder 1 fuel injector

Y76/2

Cylinder 2 fuel injector

Y76/3

Cylinder 3 fuel injector

 

Remove/install

 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-0001-01A

 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 about Common-Rail components

AH07.16-P-0002-01TX

1

Remove interior flap above engine

AR88.40-P-1100-03MCC

 Installation: Install interior flap above the engine only after the leak test.

2

Unscrew union nuts of the injection lines (1) from the rail (2)

 Union nut, pressure line to rail

*BA07.16-P-1012-01E

3

Unscrew union nuts of the injection lines (1) from the fuel injectors (Y76/1, Y76/2, Y76/3) and remove injection lines (1)

 Installation: The injection lines (1) must always be replaced after they are released.

 Union nut, pressure line to injector

*BA07.16-P-1011-01E

 Socket wrench

*611589000300

4

Seal connections on the rail (2) and on the fuel injectors (Y76/1, Y76/2, Y76/3) with suitable stop plugs

5

Install in the reverse order

 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

6

Perform engine test run and check injection lines (1) for leak tightness

 Common rail diesel injection (CDI)

Number

Designation

Engine 660.950/951

BA07.16-P-1011-01E

Union nut, pressure line to injector

Nm

22

 Common rail diesel injection (CDI)

Number

Designation

Engine 660.950/951

BA07.16-P-1012-01E

Union nut, pressure line to rail

Stage 1

Nm

20

Stage 2

°

60