Removing/installing injection lines of common rail diesel injection (CDI)

AR07.16-P-1080TI

Removing/installing injection lines of common rail diesel injection (CDI)

8.1.09

 

Removing/installing

 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 engine

Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp 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 jets or leakage.

Keep all ignition sources out of hazard area.

Do not carry out any work on systems when they are under pressure

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 contact with fuel.

No fire, sparks, open flames or smoking.
Only pour fuels 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-1150TI

2

Remove engine intake air duct downstream of air filter

AR09.10-P-8130TI

3

Remove soundproofing (20)

 The cyclone separator must be removed when removing the right soundproofing (20).

4

Unclip leak oil line (3) at the injectors

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

AR07.03-P-9105A

 Installation: Ensure that the securing device (2) is mounted correctly and is firmly latched in the injector.

5

Remove bracket (4) of engine wiring harness

6

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 before opening.

 Union nut for pressure line on rail

*BA07.16-P-1028-01C

 Union nut for pressure line on injector

*BA07.16-P-1029-01C

7

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:



Removing/installing rail

AR07.03-P-1010TI

 Set of plugs

*129589009100

8

Remove bracket

 To do this, unscrew bolt (6).

9

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.

 Installation: Only tighten rail (21) after installing the injection lines (21/6).

10

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 plugs

*129589009100



Checking

11

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).

12

Install in reverse order

13

Run engine and inspect fuel system for leaks

Number

Designation

Engine 642

BA07.16-P-1025-01C

Pressure line on high pressure pump

M14

Nm

33

BA07.16-P-1026-01C

Pressure line of high-pressure pump on rail

M15

Nm

27

BA07.16-P-1028-01C

Union nut for pressure line on rail

M15

Nm

27

BA07.16-P-1029-01C

Union nut for pressure line on injector

M14

Nm

33