Remove/install rail · ar0703d1010a · Mercedes-Benz WIS

AR07.03-D-1010A

Remove/install rail

7.1.09

ENGINE 611.981 /987 in MODEL 901.6, 902.6, 903.6, 904.6

ENGINE 611.983 in MODEL 690.6

D07.16-1106-06

1 Rail

2 Rail pressure sensor

3 Pressure control valve

4 Rail pressure sensor connector of

5 Pressure regulator valve connector

6 Injection lines

7 Bolts

8 Pressure line high pressure pump-rail

9 Bracket of pressure line

10 Angled piece

11 Leak oil line

12 Fuel return line

13 Fuel return line

14 Cable duct for engine wiring harness

15 Ground cable

 	Remove/install
Danger!	Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to 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 top part of charge air manifold		AR09.41-D-1312A
2	Remove injection line (6)		AR07.16-D-1080A
3	Unplug connectors at rail pressure sensor (2) and at pressure regulator valve (3)
4	Detach bracket (9) of pressure line (8)
5	Take off pressure line (8) at rail	 Do not crimp or bend pressure line (8). Ensure scrupulous cleanliness!
			*BA07.16-P-1002-01A
6	Detach fuel return flow line (13) at rail	 Pay attention to use of locking arm. Replace seal.	AR47.25-P-1000-01A
7	Detach fuel return flow lines (12) and leak oil line (11) at angled piece (10)
8	Detach cable duct (14), unplug connectors at the injectors and at the camshaft position sensor, lift cable duct off the rail
9	Detach rail (1) at cylinder head and take out to the rear	Installation: Tighten rail (1) fully after feeding in all of the injection lines.
			*BA07.16-P-1004-01A
		If rail is replaced:
		Fit on existing angled piece (10), replace seals.
			*BA07.16-P-1006-01A
10	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
 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
11	Inspect fuel system for leaks	 Run engine, switch off and check for leaks

 Common rail diesel injection (CDI)

Number	Designation		Engine 611.981/ 987


BA07.16-P-1002-01A	Nut, pressure line to high-pressure pump/rail	Nm	23
BA07.16-P-1004-01A	Bolt, rail to cylinder head	Nm	14
BA07.16-P-1006-01A	Banjo bolt, leak oil line to rail	Nm	20

 Common rail diesel injection (CDI)

Number	Designation		Engine 611.983


BA07.16-P-1002-01A	Nut, pressure line to high-pressure pump/rail	Nm	23
BA07.16-P-1004-01A	Bolt, rail to cylinder head	Nm	14
BA07.16-P-1006-01A	Banjo bolt, leak oil line to rail	Nm	20

Referenced documents

ar0716d1080a Remove/install injection lines of common rail diesel injection (CDI)
ar0941d1312a Remove/install top section of charge air distribution pipe
ar4725p100001a Disconnect fuel lines from engine, reconnect
as0000z000501a 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.
as0716z000101a Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure
as4700z000101a 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.