Remove/install injection lines of common rail direct injection

AR07.16-P-1080OLC

Remove/install injection lines of common rail direct injection

07.07.2020

Engine

654 in model 213, 238, 257

1

Cable duct

3

Electrical connectors

7

Oil separator

2

Soundproofing

6

Injection lines

8

Electrical wiring harness

 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

 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 engine air intake duct downstream of air filter.

AR09.10-P-8130OLC

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

2

Remove air filter housing.

AR09.10-P-1150OLC

3

Unclip cable duct (1) from oil separator (7).

4

Remove soundproofing (2).

5

Release and disconnect electrical connectors (3).

6

Unclip electrical wiring harness (8) from injection lines (6) and place to one side.


Do not kink electrical wiring harness (8).
Failure to observe this will result in damage to the electrical wiring harness (8).

 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

7

Unscrew the union nuts for the injection lines (6).

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

AH00.00-P-0015-01CW

 Installation: First, slightly tighten union nuts of injection lines (6) by hand, then tighten at rail and finally at fuel injectors.

 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

8

Remove injection lines (6) and catch escaping fuel using rags.

 Installation: Replace injection lines (6).

9

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


Ensure utmost cleanliness.
Otherwise, leaks and malfunctions occur.

 Plug

*963589019100

 Record plug

*129589009100

10

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

11

Perform an engine test run; check the fuel injection system for leaks.

12

Install upper engine cover.

AR01.10-P-2405OLC

 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