Remove/install injection lines of common rail direct injection

AR07.16-P-1080OGW

Remove/install injection lines of common rail direct injection

11.07.2018

Model

213, 238, 253 with engine 642

1

Vacuum line

2

engine wiring harness cable duct

3

Bracket

5

Injection lines

6

Injection lines

 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

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

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

AH00.00-P-0015-01CW

Notes about Common-Rail components

AH07.16-P-0002-01TX



Remove

1

Remove right and left air filter housings.

AR09.10-P-1150OGW

2

Remove engine air intake duct downstream of air filter.

AR09.10-P-8130OGW

3

Remove leak oil lines from fuel injectors.

AR07.03-P-9110OGW

4

Remove vacuum line (1) from vacuum pump.

5

Remove vacuum line (1) at engine wiring harness cable duct (2) and at bracket (3).

6

Unclip engine wiring harness cable duct (2) (arrows).

 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

7

Unscrew union nuts from injection lines (5, 6).

 Open double hexagon box wrench

*454589000300

 Box wrench bit

*000589680300

8

Remove injection lines (5, 6) and seal openings with suitable stop plugs.


Do not crush or deform injection lines (5, 6).
Leaks and damage will occur otherwise.

 Plug

*963589019100

 Record plug

*129589009100

9

Remove pressure line between high-pressure pump and left rail and seal openings with suitable stop plugs.


Do crush or deform pressure line between high-pressure pump and left rail.
Leaks and damage will occur otherwise.

 Open double hexagon box wrench

*454589000300

 Box wrench bit

*000589680300

 Record plug

*129589009100

10

Loosen left rail.

AR07.03-P-1011OGW

11

Loosen right rail.

AR07.03-P-1012OGW



Check

12

Check sealing cones of injection lines (5, 6) and pressure line for pressure marks.

If there is a problem:



Replace corresponding component.



Install

13

Install injection lines (5, 6) and pressure line between high-pressure pump and left rail such that they are free of tension and tighten union nuts slightly by hand.

14

Tighten left rail.

AR07.03-P-1011OGW

15

Tighten right rail.

AR07.03-P-1012OGW

16

Tighten pressure line between high-pressure pump and left rail.

 Pressure line to high-pressure pump to rail

*BA07.16-P-1026-01C

 Pressure line to high-pressure pump

*BA07.16-P-1025-01C

 Fuel line to cylinder head cover / lifting eye / charge air manifold

*BA07.16-P-1022-01C

 Open double hexagon box wrench

*454589000300

 Box wrench bit

*000589680300

17

Tighten injection lines (5, 6).

 Union nut, pressure line to rail

*BA07.16-P-1028-01C

 Union nut, pressure line to injector

*BA07.16-P-1029-01C

 Open double hexagon box wrench

*454589000300

 Box wrench bit

*000589680300

18

Clip in engine wiring harness cable duct (2) (arrows).

19

Attach vacuum line (1) to engine wiring harness cable duct (2) and to bracket (3).

20

Attach vacuum line (1) to vacuum pump.

21

Attach leak oil lines to fuel injectors.

AR07.03-P-9110OGW

22

Install engine air intake duct downstream of air filter.

AR09.10-P-8130OGW

23

Install right and left air filter housings.

AR09.10-P-1150OGW

 Installation: Only install upper engine cover after the leak test.

 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

24

Perform engine test run; in this connection, check fuel system for leak tightness.

25

Install upper engine cover.

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1022-01C

Fuel line to cylinder head cover / lifting eye / charge air manifold

M612

Nm

9

M615

Nm

14

M619

Nm

-

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1025-01C

Pressure line to high-pressure pump

M14

Nm

33

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1026-01C

Pressure line to high-pressure pump to rail

M15

Nm

27

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1028-01C

Union nut, pressure line to rail

M15

Nm

27

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1029-01C

Union nut, pressure line to injector

M14

Nm

33