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

AR07.16-S-1080SE

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

16.8.10

27.5.10

Information on problem reports added

Operation step 3

 

Remove/install

 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 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 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 engine air intake duct downstream of air filter

AR09.10-S-8130SE

2

Remove noise damper for turbocharger

AR09.40-S-6920SE

3

Remove covers from cylinder head covers

Cover on left cylinder head cover

AR01.20-D-5015SG

Cover on right cylinder head cover

AR01.20-D-5015SF

4

Unclip leak oil line (3) at the injectors

AR07.03-S-9105SE

5

loosen bracket on cylinder head cover and lay down to side

 For this purpose unscrew bolts (2) on left rail (21) on cylinder head cover.



*BA07.16-N-1013-01B

6

Unscrew union nut (5) from injection lines (24)

 When working on injection system pay particular attention to cleanliness to prevent damage from soiling. Clean separation points before opening.

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



*BA07.16-N-1011-01B



*BA07.16-N-1012-01B

 Box wrench bit

*000589680300

Open-double-hexagon-box wrench
width across flats 18

gotis://A_02_01.0

7

Remove injection lines (24)

 Immediately close all connections on injection lines (24) to prevent against soiling; do not damage injection lines (24).

Installation: Loosen rail (21) to assemble the injection lines (24) free of tension. Do not retighten the bolts until all injection lines (24) have been inserted, see:



Remove/install rail

AR07.03-S-1010SE

 Set of stop plugs

*129589009100



Checking

8

Check sealing cone on injection lines (24)

 Installation: Replace injection lines (24) if damaged or if pressure marks are present.

9

Install in the reverse order

 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 from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

10

Check for leaks with engine running

Number

Designation

Engine
642.890/990

BA07.16-N-1011-01B

Pressure line union nut to rail

M151

Stage 1

Nm

27

Stage 2

°

-

BA07.16-N-1012-01B

Pressure line union nut to injector

M141.5

Stage 1

Nm

33

Stage 2

°

-

BA07.16-N-1013-01B

Bolt, rail to cylinder head

Nm

14