Remove/install high pressure line

AR07.16-P-1002MFF

Remove/install high pressure line

07.07.2020

Engine

654 in model 118, 177, 247

Modification notes

22.01.2020

Document completely revised.

5

Heat shield

6

Bolts

7

Bolts

8

Oil filter cover

10

Fuel hose

11

Fuel hose

1

High pressure pipe

2

Union nut

3

Bolts

10

Fuel hose

12

Electrical connectors

13

Screw

14

Coolant line

15

Bolts

16

Fuel line

 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

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

 

Remove/install

1

Remove oil filter cover (8) with oil filter element.



AP18.00-P-0101FA

 Installation: Replace oil filter element and O-ring.

 Assembly tool

*000589936300

2

Remove the throttle valve actuator.

AR07.70-P-0005MFF

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

3

Release and disconnect electrical connectors (12).

4

Remove screw (13).

 M61

*BA00.10-P-1002-04A

5

Remove coolant line (14) from crankcase and place to one side.

6

Remove screw/bolts (6).

 M61

*BA00.10-P-1002-04A

 Screw, heat shield to fuel line

*BA07.16-P-1010-04A

7

Remove the heat shield (5).

8

Remove leak oil line from high-pressure pump.

AR07.03-P-9105MFF

9

Remove screw/bolts (15).

 Bolt, fuel line to high-pressure pump

*BA07.16-P-1009-04A

 M61

*BA00.10-P-1002-04A

10

Remove fuel line (16) from high-pressure pump as well as crankcase and place to one side.

 Installation: Replace O-ring.

 Assembly tool

*000589936300

11

Seal high-pressure pump and fuel line (16) with suitable stop plugs.

 Record plug

*129589009100

12

Remove fuel hose (10) from high-pressure pump and place to one side.

 Installation: Replace O-ring.

 Assembly tool

*000589936300

13

Seal fuel hose (10) and high-pressure pump with suitable stop plugs.

 Record plug

*129589009100

14

Remove screws (7).

 M61

*BA00.10-P-1002-04A

15

Place fuel hose (11) to one side somewhat.

16

Remove screw/bolts (3).

 Bolt, pressure line clamp to charge air distributor

*BA07.16-P-1011-04A

17

Remove union nuts (2) of the high-pressure line (1) from the high-pressure pump and rail.

Tighten high-pressure line from high-pressure fuel pump to Common Rail Direct Injection

AR07.16-P-0001-02MFF

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

AH00.00-P-0015-01CW

 Use rags to catch escaping fuel.

 Installation: Tighten union nut (2) at the high-pressure pump with  engine mount wrench set in combination with torque tool set.

 Commercially available devices/tools
Torque tool set

 Union nut, pressure line to rail

*BA07.16-P-1002-04A

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

*BA07.16-P-1003-04A

 Open double hexagon box wrench

*454589000300

 Engine mount wrench set

*001589011600

18

Remove the high-pressure line (1).

 Use rags to catch escaping fuel.

19

Seal openings on the rail and high-pressure pump with suitable stop plugs.

 Record plug

*129589009100

20

Remove clamps from the high-pressure line (1).

 Installation: Replace high-pressure line (1).

21

Install in the reverse order.



Check

 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

22

Perform engine test run and check engine in area of high-pressure line (1) for leaks.

23

Install top engine cover.

AR01.10-P-2405MFF

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1002-04A

Union nut, pressure line to rail

Nm

27

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1003-04A

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

Nm

33

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1009-04A

Bolt, fuel line to high-pressure pump

Nm

8

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1010-04A

Screw, heat shield to fuel line

Nm

8

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1011-04A

Bolt, pressure line clamp to charge air distributor

Nm

8