Remove/install injection lines of common rail direct injection

AR07.16-P-1080OLB

Remove/install injection lines of common rail direct injection

04.09.2018

Engine

651 in model 117, 156, 176

Engine

651 in model 246

1

Injection lines

5

Vacuum hose

B6/1

Camshaft Hall sensor

2

High-pressure line

6

Wiring shaft

3

Rail

7

Engine wiring harness

2

High-pressure line

3

Rail

8

Screw/bolt

9

High-pressure pump

 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

 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

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove cylinder head cover trim

AR01.20-P-5014-02OLB

Remove injection line (1)

2

Detach vacuum hose (5) at connection fitting and press to the side

3

Unclip engine wiring harness (7) and place to one side

4

Disconnect electrical connection at camshaft Hall sensor (B6/1)

5

Unclip wiring shaft (6) from injection lines (1) upwards and place to one side

6

Unscrew union nuts for injection lines (1)


Counterhold connections for injection lines (1) in the process.
This prevents material breakages from occurring.

 Box wrench bit

*000589690300

7

Remove injection lines (1)


After disassembly of the injection lines (1), all connections must be closed off.
In this way one can avoid damage to high pressure components.

 Installation:
Replace injection lines (1) and install free of tension.
Leaks can occur otherwise.

 Installation:
For assembly the markings on the injection lines (1) for the 3rd and 4th cylinder must be on the side of the rail (3).
Leaks can occur otherwise.

 Stop plugs are available as an ET of the fuel injection system. See EPC Group 07. Ensure scrupulous cleanliness.

 Union nut, pressure line to injector/ rail

*BA07.16-P-1009-01H

Remove high-pressure line (2)

8

Remove exhaust gas recirculation actuator

AR14.20-P-7662OLB

9

Remove screw/bolts (8) on high-pressure line (2) bracket

10

Unscrew and remove high-pressure line (2) from the high-pressure pump (9) and rail (3)


After disassembly of the high-pressure lines (2), all connections must be closed off.
In this way one can avoid damage to high pressure components.

 Installation:
Replace high-pressure line (2) and install free of tension.
Leaks can occur otherwise.

 Stop plugs are available as an ET of the fuel injection system. See EPC Group 07. Ensure scrupulous cleanliness.

 Counterhold connection fitting during loosening to avoid it from coming loose as it is being loosened.

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

*BA07.16-P-1002-01H

 Box wrench bit

*000589690300

11

Clean high-pressure pump (9) in the area of connection fitting with cold cleaning solvent and blow dry with compressed air

 Use absorbent, lint-free cloth to collect escaping fuel.

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A

 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

Check fuel system for leaks with engine running

12

Install in the reverse order

 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-1009-01H

Union nut, pressure line to injector/ rail

Nm

33

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-04A

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

Chemische Werke Kluthe GmbH
Gottlieb-Daimler-Str. 12
69115 Heidelberg
Germany
Tel. +49 6221 5301-0
Fax +49 6221 5301-176
http://kluthe.com