Remove/install injection lines of common rail direct injection

AR07.16-S-1080PS

Remove/install injection lines of common rail direct injection

18.04.2019

Engine

642 in model 470, 471

Modification notes

17.04.2019

Work procedure revised, notes and special tools updated

The whole document

1

Injection lines

4

High pressure pipe

7

Screw

2

Cable duct

5

Cable duct

8

Oil separator

3

Electrical connector

6

Bolts

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

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

AH00.00-P-0015-01CW



Remove

1

Remove upper section of right and left air filter housing.



Replace air filter element

AP09.10-S-0980PS

2

Remove clean air line.

AR09.10-S-8140PS

3

Release and remove leak oil line at fuel injectors.

AR07.03-S-9110PS

 WIS Service Media
wsm://04_201800_43
Operation steps 3, 5, 6 are shown on injection line (1) of cylinder 5 .

4

Remove union nut of injection line (1) of fuel injector of cylinder 6  at rail.

 For this purpose, detach cable duct (2) and press to one side.

 Open double hexagon box wrench

*454589000300

5

Remove remaining union nuts of injection lines (1).

 Box wrench bit

*000589680300

 Open double hexagon box wrench

*454589000300

6

Remove injection lines (1).


Do not crush or deform injection lines (1).
Leaks and damage will occur otherwise.

 Plug openings.

 Record plug

*129589009100



Install

7

Remove screw (7).

8

Detach cable duct (5).

 Slightly lift cable duct (5) (arrows).

9

Release union nut of high-pressure line (4) at high-pressure pump by a few revolutions.

 Box wrench bit

*000589680300

10

Remove high-pressure line (4) at rail.


Do not crush or deform high-pressure line (4).
Leaks and damage will occur otherwise.

 Plug openings.

 Open double hexagon box wrench

*454589000300

 Record plug

*129589009100

11

Remove electrical connector (3) at oil separator (8).

 Do not disconnect the electrical connector (3).
Place electrical connector (3) outside of working area.

12

Remove screw/bolts (6).



Check

13

Check sealing cones of injection lines (1) and high-pressure line (4) for pressure marks.

If pressure marks exist



Replace corresponding injection lines (1) and/or high-pressure line (4).

14

Install injection lines (1).

 For this purpose, slide injection lines (1) by hand up to end stop into their mounts and slightly tighten union nuts by hand.

15

Install high-pressure line (4).

 For this purpose, attach high-pressure line (4) to rail and slightly tighten union nuts at rail and high-pressure pump by hand.

16

Attach cable duct (5).

17

Screw in bolts (6).

 Bolt, rail to cylinder head cover

*BA07.16-N-1012-03PS

18

Install electrical connector (3) at oil separator (8).

19

Tighten union nuts of high-pressure line (4).

 Union nut, high-pressure line for fuel system high pressure pump to rail

*BA07.16-N-1007-03PS

 Union nut, high-pressure line for fuel system high pressure pump to fuel system high pressure pump

*BA07.16-N-1008-03PS

 Box wrench bit

*000589680300

 Open double hexagon box wrench

*454589000300

20

Screw in screw/bolt (7).

 Bolt, high-pressure line retaining clamp to cylinder head cover/charge-air distributor

*BA07.16-N-1013-03PS

21

Tighten union nut of injection line (1) of fuel injector of cylinder 6  at rail.

 Union nut, high-pressure line for fuel injector to rail

*BA07.16-N-1006-03PS

 Open double hexagon box wrench

*454589000300

22

Attach cable duct (2).

23

Tighten remaining union nuts of injection lines (1).

 Union nut, high-pressure line for fuel injector to fuel injector

*BA07.16-N-1005-03PS

 Union nut, high-pressure line for fuel injector to rail

*BA07.16-N-1006-03PS

 Box wrench bit

*000589680300

 Open double hexagon box wrench

*454589000300

24

Attach leak oil line to fuel injectors.

AR07.03-S-9110PS

25

Install clean air line.

AR09.10-S-8140PS

26

Install upper section of right and left air filter housing.



Replace air filter element

AP09.10-S-0980PS

 Only install upper engine cover after the leak test.



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

27

Check fuel system for leaks with engine running.

 Visual inspection only.

28

Install upper engine cover.

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1005-03PS

Union nut, high-pressure line for fuel injector to fuel injector

Stage 1

Nm

20

Stage 2

°

60

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1006-03PS

Union nut, high-pressure line for fuel injector to rail

Stage 1

Nm

20

Stage 2

°

60

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1007-03PS

Union nut, high-pressure line for fuel system high pressure pump to rail

Stage 1

Nm

20

Stage 2

°

60

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1008-03PS

Union nut, high-pressure line for fuel system high pressure pump to fuel system high pressure pump

Stage 1

Nm

20

Stage 2

°

60

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1012-03PS

Bolt, rail to cylinder head cover

Nm

14

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1013-03PS

Bolt, high-pressure line retaining clamp to cylinder head cover/charge-air distributor

Nm

9