Remove/install right rail

AR07.03-P-1012OGW

Remove/install right rail

11.07.2018

Engine

642 in model 213, 238, 253

1

Right rail

2

Engine wiring harness guide

3

Injection line

4

High pressure pipe

5

Screw

7

Screw

 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 injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

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 the oil separator.

AR01.20-P-9750OGW

 Installation: Only install upper engine cover after the leak test.

2

Unclip engine wiring harness guide (2) on right side.

 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

3

Remove injection lines (3).

AR07.16-P-1080OGW

4

Unscrew union nut for high-pressure line (4).

 Fuel line between left and right tail

*BA07.16-P-1024-01C

 Open double hexagon box wrench

*454589000300

5

Remove high-pressure line (4) on charge-air distributor.

 Fuel line to cylinder head cover / lifting eye / charge air manifold

*BA07.16-P-1022-01C

6

Release and disconnect electrical connector of fuel high pressure sensor (B4/6) on right rail (1).

7

Expose electrical wiring harness on right rail (1).

 Installation: Replace cable tie.

8

Remove bolts (5).

 Bolt, rail to cylinder head

*BA07.16-P-1003-01C

9

Unscrew screw (7) and remove bracket.

 Engine 642 in model 238Right engine ground point

*BA00.19-P-1036-02B

 Engine 642 in model 213Right engine ground point

*BA00.19-P-1040-02A

 Engine 642 in model 253Right engine ground point

*BA00.19-P-1041-01E

10

Remove right rail (1).

11

Check sealing cones of high-pressure line (4) for pressure marks.

If there is a problem:



replace high-pressure line(4).

12

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

13

Perform engine test run, checking the fuel system in terms of leak tightness.

14

Install upper engine cover.

 Ground points

Number

Designation

Model 238

BA00.19-P-1036-02B

Right engine ground point

W21

Nm

9

 Ground points

Number

Designation

Model 213

BA00.19-P-1040-02A

Right engine ground point

W21

Nm

9

 Ground points

Number

Designation

Model 253 (except 253.99)

BA00.19-P-1041-01E

Right engine ground point

W21

Nm

9

 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-1022-01C

Fuel line to cylinder head cover / lifting eye / charge air manifold

M612

Nm

9

M615

Nm

14

M619

Nm

-

 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