Remove/install rail

AR07.03-P-1010OLD

Remove/install rail

17.9.15

Engine

651 in model 205, 253

1

Screw/bolt

9

High-pressure line

2

Cover

B4/7

Fuel pressure sensor

5

Rail

B60

Exhaust pressure sensor

6

Vacuum line

B76/1

Condensation sensor for fuel filter with heating element

7

Engine wiring harness

M55

Intake port shutoff actuator motor

8

Screw/bolt

X214

Glow plug electrical connection

3

Fuel return line

4

Screw/bolts

5

Rail

B4/6

High pressure fuel pressure sensor

Y74

Pressure regulating valve

 

Remove/install

1

Remove engine cover

2

Remove injection lines

AR07.16-P-1080OLD

 Installation:
When mounting the injection lines for cylinder 3 and 4, the black marking must be located at the side of the rail (5).
Leaks can occur otherwise.

 Installation: Replace injection lines and install free of tension.

3

Remove screw/bolt (1) and remove cover (2)

4

Disconnect electrical connection at fuel filter condensation sensor with heating element (B76/1)

5

Disconnect electrical connection at intake port shutoff actuator motor (M55)

6

Disconnect electrical connection at pressure regulating valve (Y74)

7

Disconnect electrical connection on high pressure fuel pressure sensor (B4/6)

8

Disconnect electrical connection at exhaust pressure sensor (B60)

9

Disconnect electrical connection on the fuel pressure sensor (B4/7)

10

Detach vacuum line (6) to vacuum pump at connecting point

 The vacuum line (6) runs along the firewall and the connecting point is located in the area of the oil dipstick.

11

Unclip engine wiring harness (7) at the retaining clip (arrows) and raise somewhat

12

Unclip vacuum line (6) at engine wiring harness (7) and place to one side

13

Disconnect glow plug electrical connection (X214)

14

Unscrew banjo bolt on fuel return line (3)


Plug all connections.
Damage can occur to the high-pressure components otherwise.

 Grommets are available as a replacement part of the fuel injection system; see EPC Group 07. Re-use is not permissible. Ensure scrupulous cleanliness!

 Use rags to catch escaping fuel.

 Installation: Install new sealing rings.

 Banjo bolt, return line to rail

*BA07.16-P-1004-01H

15

Unscrew union nut for the high-pressure line (9) on rail (5)

 Use rags to catch escaping fuel.

 Union nut, pressure line to high-pressure pump/rail

*BA07.16-P-1002-01H

 Box wrench bit

*000589690300

16

Remove screw/bolt (8) for high-pressure line (9) at charge air distributor


Do not crimp or bend high-pressure line (9).
The fuel system may experience malfunctions otherwise.

17

Check high-pressure line (9) for damage

If complaint present



Replace high-pressure line (9)

AR07.16-P-1080OLD

18

Detach electrical wiring harness at rail (5)

 The electrical wiring harness is fastened with cable ties to the rail (5).

19

Remove screw/bolts (4)

 Screw/bolt, rail to cylinder head

*BA07.16-P-1003-01H

20

Take out rail (5)


Plug all connections.
Damage can occur to the high-pressure components otherwise.

 Grommets are available as a replacement part of the fuel injection system; see EPC Group 07. Re-use is not permissible. Ensure scrupulous cleanliness!

21

Install in the reverse order



Check

 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

22

Check fuel system for leaks with engine running

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1002-01H

Union nut, pressure line to high-pressure pump/rail

Nm

33

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1003-01H

Screw/bolt, rail to cylinder head

Nm

14

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1004-01H

Banjo bolt, return line to rail

Nm

25