Remove/install injection lines of common rail direct injection

AR07.16-P-1080OLF

Remove/install injection lines of common rail direct injection

04.09.2018

Engine

651 in model 222

7

Electrical connection

B6/1

Camshaft Hall sensor

8

Cable duct

Y76

Fuel injectors

9

Injection line

10

Bracket

13

Screw/bolt

16

Rail

11

Mounting plate

14

Screw/bolt

17

High-pressure fitting

12

High-pressure line

15

High-pressure pump

67

Exhaust gas recirculation cooler bypass switchover valve

 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

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove upper engine cover

2

Disconnect Electrical connections (7)

 Installation: Replace sealing rings and housing cover on the electrical connections (7).

 Press safety catch with needle nose pliers together.

3

Unclip cable duct (8) from injection lines (9) upwards and place to one side

4

Unscrew union nuts for injection lines (9)


Counterhold connections for injection lines (9).
Damage is avoided in this way.

 Installation: Lay union nut on fuel injectors (Y76) finger-tight. Only tighten union nuts on fuel injectors (Y76) after tightening the union nuts on the rail (2).

 Union nut, pressure line to injector/ rail

*BA07.16-P-1009-01H

 Box wrench bit

*000589690300

5

Remove injection lines (9) and close off connections at rail (16) and fuel injectors (Y76)

 Installation:
Always replace injection lines (9). Ensure utmost cleanliness. Do not crush or bend injection lines (9).
Leaks and damage nay occur otherwise.

 Installation:
When mounting the injection lines (9) for cylinder 3 and 4 ensure that the markings must be located at the side of the rail.
Leaks can occur otherwise.

 Grommets are available as an replacement part of the fuel injection system; see EPC Group 07. The grommets may only be used once.

6

Remove exhaust gas recirculation valve

AR14.20-P-7662OLF

7

Remove screw/bolts (13, 14) on high-pressure line (12) bracket

8

Detach exhaust gas recirculation cooler bypass switchover valve (67) with attached lines from holder (10) and place to one side

9

Remove bracket (10)

 Bolt, bracket for electric switchover valves to fastening plate

*BA09.41-P-1006-01N

10

Remove mounting plate (11)

 Charge air manifold fastening plate bolt on engine support

*BA09.41-P-1005-01N

11

Unscrew union nuts for high-pressure line (12) to high-pressure pump (15) and on rail (16)

 In order to avoid unfastening of the high-pressure fitting (17); counterhold these for unfastening the union nut. Ensure scrupulous cleanliness!

 Installation: Check sealing cone at high-pressure line (12) for damage; if necessary replace high-pressure line (12). Install high-pressure line (12) free of tension.

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

*BA07.16-P-1002-01H

 Box wrench bit

*000589690300

12

Remove high-pressure line (12) and close off connections at high-pressure pump (15) and rail (16)

 Grommets are available as an replacement part of the fuel injection system; see EPC Group 07. The grommets may only be used once.

13

Clean high-pressure pump (15) in the area of high-pressure fitting (17) and blow dry with compressed air

 Use clean absorbent, lint-free cloth to collect escaping fuel that runs out.

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A

14

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

15

Carry out an engine test run and check fuel injection systems for leaktightness

 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

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1005-01N

Charge air manifold fastening plate bolt on engine support

Nm

20

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1006-01N

Bolt, bracket for electric switchover valves to fastening plate

Nm

9

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