Remove/install injection lines of common rail diesel injection (CDI)

AR07.16-P-1080PI

Remove/install injection lines of common rail diesel injection (CDI)

8.1.09

 

Remove/install

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it moving off. Wear closed and close-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Danger!

Risk of explosion from 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 and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove air filter housing

AR09.10-P-1150PI

2

Remove engine intake air duct downstream of air filter

AR09.10-P-8130PI

3

Unclip leak oil line (3) at the injectors

 Pull fuse (2) upwards and remove leak oil line (3).

AR07.03-P-9105A

 Installation: Push securing device (2) downwards until it engages audibly.

4

Unscrew bracket (4) of engine wiring harness

5

Undo union nuts (5) of injection lines (21/6)

 Pay attention to the different tightening torques otherwise the injectors or the rail (21) could be damaged.

 When working on the injection system ensure scrupulous cleanliness! Clean separation points prior to opening to prevent the ingress of dirt.

 Pressure line union nut on rail

*BA07.16-P-1028-01C

 Pressure line union nut on injector

*BA07.16-P-1029-01C

 Box wrench bit

*000589680300

Open socket SW18

6

Remove injection lines (21/6)

 Close all connections of injection lines (21/6) immediately after removal as a protection against contamination. Do not crush or deform injection lines (21/6).

 Installation: Loosen rail (21) to assemble the injection lines (21/6) free of tension. Do not retighten the bolts until all injection lines (21/6) have been inserted, see:



Remove/install rail

AR07.03-P-1010PI

 Set of stop plugs

*129589009100

7

Remove bracket

Remove bolt (6).

8

Loosen rail (21)

 Installation: If all injection lines (21/6) are detached then the rail (21) must also be loosened and the injection lines (21/6) must be pushed in by hand all the way.

9

Remove compressed air line (19/1)

 Close all connections of pressure lines (19/1) immediately after removal as a protection against contamination. Do not crush or deform pressure line (19/1).

 Pressure line to high-pressure pump

*BA07.16-P-1025-01C

 Pressure line of high pressure pump to rail

*BA07.16-P-1026-01C

 Set of stop plugs

*129589009100

 Box wrench bit

*000589680300

Open socket SW18



Checking

10

Inspect taper gasket of injection lines (21/6) and pressure line (19/1)

 Installation: If pressure marks are found, replace the injection lines (21/6) and the pressure line (19/1).

11

Install in the reverse order

12

Check fuel system for leaks with engine running

Number

Designation

Engine 642

BA07.16-P-1025-01C

Pressure line to high-pressure pump

M14

Nm

33

BA07.16-P-1026-01C

Pressure line to high-pressure pump to rail

M15

Nm

27

BA07.16-P-1028-01C

Pressure line union nut to rail

M15

Nm

27

BA07.16-P-1029-01C

Pressure line union nut to injector

M14

Nm

33