Remove/install injection lines of common rail direct injection

AR07.16-P-1080MFF

Remove/install injection lines of common rail direct injection

07.07.2020

Engine

654 in model 118, 177, 247

Modification notes

29.11.2019

Document completely revised.

1

Cable duct

3

Electrical connector

5

Injection lines

2

Noise damper

4

Bracket

 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

 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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-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

Switch off ignition and store transmitter key outside of transmitter range (min. 2 m).

2

Remove engine charge air duct from exhaust gas turbocharger.

AR09.41-P-8622MFF

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

3

Release and disconnect electrical plug (3) and unclip from the bracket (4).

4

Unclip electrical wiring harness from the bracket (4).

 Clip remover

*452589016300

5

Remove bracket (4) from the cylinder head cover and place to one side.

 Bolt, bracket for engine cover to cylinder head cover

*BA01.10-P-1003-01D

6

Unclip cable duct (1).

7

Remove noise damper (2).

8

Release and disconnect electrical connectors from the fuel injectors.

9

Unclip electrical wiring harness from the injection lines(5) and place to one side.


Do not kink electrical wiring harness.
Failure to observe this will result in damage to the electrical wiring harness.

10

Remove union nuts of injection lines (5).

AR07.16-P-0001-01MFF

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

AH00.00-P-0015-01CW

 Installation: Observe tightening procedure.

 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

 Box wrench bit

*000589680300

11

Remove the injection lines (5) and capture escaping fuel with suitable rags.

 Installation: Install new injection lines(5).

12

Seal connections on rail and fuel injectors with suitable stop plugs.

 Record plug

*129589009100

13

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

14

Perform engine test run and check engine for proper operation and leak tightness.

15

Install upper engine cover.

AR01.10-P-2405MFF

 Engine cover

Number

Designation

Engine 654

BA01.10-P-1003-01D

Bolt, bracket for engine cover to cylinder head cover

Nm

8

 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