Remove/install rail

AR07.03-D-1010WE

Remove/install rail

18.04.2019

Engine

651 in model 900

Engine

651.955/956/957 in model 906

1

Rail

5

Fuel pressure line

9

Screw

2

Fuel return line

6

Electrical wiring harness

10

Electrical connector

3

Banjo bolt

7

Engine wiring harness cable duct

B4/16

Rail pressure sensor

4

Electrical connector

8

Screw

Y74/5

Pressure regulator valve

 

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

 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

Notes about Common-Rail components

AH07.16-P-0002-01TX

1

Remove injection lines

AR07.16-D-1080WE

2

Release engine wiring harness cable duct (7) and press as far as possible to side in area of rail (1)

AR01.00-D-2411-01WE

3

Disconnect electrical connector (10) at rail pressure sensor (B4/16)

4

Disconnect electrical connector (4) at pressure regulating valve (Y74/5)

5

Remove electrical wiring harness (6) at rail (1)

 Installation: Replace cable tie.

6

Remove banjo bolt (3) of fuel return line (2)

 Use rags to catch escaping fuel.

 Installation: Install new sealing rings.

 Banjo bolt, return line to rail

*BA07.16-N-1020-01A

7

Unscrew union nut of fuel pressure line (5) at rail (1)

 Use rags to catch escaping fuel.

 Use open end wrench bit 17 mm from tool kit to tighten union nuts.

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

*BA07.16-N-1019-01A

 Tool kit

*000589109900

Check fuel pressure line (5) for damage, replace if necessary. Refer to:



Remove/install fuel pressure line

AR07.03-D-7000WE

8

Unscrew screw (8) of fuel pressure line (5)

 Do not crush or bend fuel pressure line (5).

 Installation: Check fuel pressure line (5) for damage, replace if necessary.

Refer to:



Remove/install fuel pressure line

AR07.03-D-7000WE

9

Remove screw/bolts (9)

 Bolt, rail to cylinder head

*BA07.16-N-1007-01A

10

Remove rail (1)

11

Seal connections at rail (1), fuel pressure line (5) and fuel return line (2) with suitable stop plugs

 Record plug

*129589009100

12

Install in the reverse order

 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

13

Perform engine test run, switch off engine and check fuel system in area of rail (1) for leaks

 Common rail diesel injection (CDI)

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA07.16-N-1007-01A

Bolt, rail to cylinder head

Nm

14

14

 Common rail diesel injection (CDI)

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA07.16-N-1019-01A

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

Stage 1

Nm

7

7

Stage 2

Nm

33

33

 Common rail diesel injection (CDI)

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA07.16-N-1020-01A

Banjo bolt, return line to rail

Nm

32

32