Remove/install rail

AR07.03-P-1010PI

Remove/install rail

11.06.2019

Engine

642 in model 203, 209

Modification notes

11.06.2019

Document completely revised.

1

Screw

19/1

Pressure line

B4/6

Rail pressure sensor

2

Return flow pipe

19/2

Fuel line

Y74

Pressure regulator valve

3

Union nuts

21

Rails

 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

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

AH00.00-P-0015-01CW

 

Remove/install

1

Remove engine cover.

AR01.10-P-2405PI

 Installation: Do not install engine cover until after the leak test.

2

Remove injection lines.

AR07.16-P-1080PI

 Installation: Replace injection lines.

3

Release and disconnect electrical connector from the rail pressure sensor (B4/6).

When removing the right rail (21).

4

Release and disconnect electrical connector from the pressure regulating valve (Y74).

When removing left rail (21).

5

Remove return line (2).

6

Unscrew union nuts (3) of the pressure line (19/1).

 Counterhold while loosening the union nuts (3) from the connection fitting of the pressure line (19/1).

 Installation: Counterhold while tightening the union nuts (3) on the connection fitting of the pressure line (19/1).

 Pressure line to high-pressure pump

*BA07.16-P-1025-01C

 Pressure line to high-pressure pump to rail

*BA07.16-P-1026-01C

 Box wrench bit

*000589680300

7

Remove pressure line (19/1).

 Installation: Install new pressure line (19/1).

8

Unscrew union nuts (3) of the fuel line (19/2).

 Installation: Replace fuel line (19/2).

 Fuel line between left and right tail

*BA07.16-P-1024-01C

 Box wrench bit

*000589680300

9

Remove bolts (1).

 Bolt, rail to cylinder head

*BA07.16-P-1003-01C

10

Remove rails (21).

 Installation: Tighten union nuts (3) of the fuel line (19/2) and pressure line (19/1) slightly by hand.

11

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

12

Check fuel system for leaks with engine running.

13

Install engine cover.

AR01.10-P-2405PI

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1003-01C

Bolt, rail to cylinder head

Nm

14

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1024-01C

Fuel line between left and right tail

M15

Nm

27

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1025-01C

Pressure line to high-pressure pump

M14

Nm

33

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1026-01C

Pressure line to high-pressure pump to rail

M15

Nm

27