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

AR07.16-P-1080CD

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

24.4.12

 

Remove/install

 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



Notes about Common-Rail components

AH07.16-P-0002-01TX

1

Remove cylinder head cover trim

2

Remove section for partition wall on the left and the center

Model 166

Remove injection line (9)

3

Disconnect electrical connectors (7)

4

Unclip wiring shaft (8) from injection lines (9) upwards and place to one side.

5

Unscrew union nuts for injection lines (9)

 In the process counterhold all connections for the injection lines (9) . Material breakages can occur otherwise.



*BA07.16-P-1009-01H

 Box wrench bit

*000589690300

6

Remove injector lines (9)

 All connectors must be closed off after disassembly of the injection lines. Damage can occur to the high pressure components otherwise.

 Stop plugs are available as a replacement part for the injection system,

see EPC Group 07.

 Multiple use of the  stop plug is not permitted.

Ensure scrupulous cleanliness!

 Installation: Always replace injection lines (9) and install unstressed.

 During assembly of the injection lines (9) for cylinders 3 and 4 ensure that the marking is on the side of the rail (5) since leaks can occur otherwise.

Remove high pressure line (1)

7

Remove exhaust gas recirculation valve

Model 204, 207, 212, 218, 221

AR14.20-P-7662CD

Model 166, 172

AR14.20-P-7662GQ

8

Remove screw/bolts (2, 3) on high-pressure line (1) bracket

9

Unscrew and remove high pressure line (1) from the high pressure pump (4) and rail (5)

 Counterhold high pressure fitting (6) to avoid it from coming loose as the high pressure line is being loosened. After disassembly, close off the high pressure line (1) connections. Ensure scrupulous cleanliness!

 All connectors must be closed off after disassembly of the injection lines. Damage can occur to the high pressure components otherwise.

 Stop plugs are available as a replacement part for the injection system,

see EPC Group 07.

 Multiple use of the  stop plug is not permitted.

Ensure scrupulous cleanliness!

 Installation: Install high-pressure line (1) free of tension.



*BA07.16-P-1002-01H

 Box wrench bit

*000589690300

10

Clean high pressure pump (4) in the area of high pressure fitting (6) with cold cleaning solvent and blow dry with compressed air

 Depending on installation position, use an absorbent, lint-free cloth to collect any fuel that runs out.

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A

11

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

12

Check fuel system for leaks with engine running

Number

Designation

Engine 651

BA07.16-P-1002-01H

Union nut, pressure line to high-pressure pump/rail

Nm

33

BA07.16-P-1009-01H

Pressure line union nut on injector/ rail

Nm

33

Number

Designation

Order number

BR00.45-Z-1051-04A

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

Chemische Werke Kluthe GmbH
Gottlieb-Daimler-Str. 12
69115 Heidelberg
Germany
Tel. +49 6221 5301-0
Fax + 49 6221 5301-176
www.wuerth.de