Remove/install left rail

AR07.03-S-1011PS

Remove/install left rail

18.04.2019

Engine

642 in model 470, 471

Modification notes

17.04.2019

Work procedure revised, notes and special tools updated

The whole document

1

Rail

2

High pressure pipe

3

Electrical connector

4

Bolts

5

Return hose

6

Screw

7

Screw

8

High pressure pipe

 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

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

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/install

1

Remove charge air pipe downstream of exhaust gas turbocharger.

AR09.41-S-1333PS

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

2

Remove upper section of left air filter housing.



Replace air filter element

AP09.10-S-0980PS

3

Disconnect electrical connector (3).

4

Remove screws/bolts (4).

 Bolt, high-pressure line retaining clamp to cylinder head cover/charge-air distributor

*BA07.16-N-1013-03PS

5

Remove union nut of high-pressure line (2) at rail (1).

 Union nut, rail high-pressure line to rail

*BA07.16-N-1004-03PS

 Open double hexagon box wrench

*454589000300

6

Remove screw (7).

 Bolt, high-pressure line retaining clamp to cylinder head cover/charge-air distributor

*BA07.16-N-1013-03PS

7

Remove high-pressure line (8) from rail (1).

 Union nut, high-pressure line for fuel system high pressure pump to rail

*BA07.16-N-1007-03PS

 Open double hexagon box wrench

*454589000300

8

Remove injection lines at rail (1).

AR07.16-S-1080PS

 Installation: Also position high-pressure lines (2, 8) during attachment of injection lines so that they are free of tension and slightly tighten their union nut by hand.

9

Remove rail (1).


Do not crush or deform high-pressure lines (2, 8).
Leaks and damage will occur otherwise.

 To do so, remove the screw/bolts (6). Remove return hose (5) from rail (1). Plug openings.

 Installation: Replace snap clamp. Do not yet screw in screws (6).

 Record plug

*129589009100

 Pliers for click clamps

*171589003700



Check

10

Check sealing cone of high-pressure lines (2) for pressure marks.

If pressure marks exist



Replace high-pressure line(2).

 Union nut, rail high-pressure line to rail

*BA07.16-N-1004-03PS

 Open double hexagon box wrench

*454589000300

11

Check sealing cone of high-pressure line (8) for pressure marks.

If pressure marks exist



Replace high-pressure line(8).

AR07.16-S-1004PS

12

Install in the reverse order.



Check

 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

Check fuel system for leaks with engine running.

 Visual inspection only.

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1004-03PS

Union nut, rail high-pressure line to rail

Stage 1

Nm

20

Stage 2

°

60

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1007-03PS

Union nut, high-pressure line for fuel system high pressure pump to rail

Stage 1

Nm

20

Stage 2

°

60

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1013-03PS

Bolt, high-pressure line retaining clamp to cylinder head cover/charge-air distributor

Nm

9