Remove/install rail

AR07.03-D-1010R

Remove/install rail

16.12.2016

Engine

646 in model 909

Modification notes

22.11.2016

Remove hose on T-piece, added

Operation step 4

22.11.2016

Remove banjo bolt on rail for replacement, added

Operation step 10

Shown on model 909.633 with code MS9 (Engine version Euro 4)

1

Rail

2

Injection lines

3

High-pressure line

4

High-pressure pump

5

Banjo bolt

6

Screw/bolts

7

Hose

8

Cable duct

9

Electrical connection

10

Electrical connection

11

Screw/bolts

12

T-piece

B4/6

Fuel pressure sensor

Y74

Pressure regulating valve

 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

 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

 

Remove/install

1

Remove injection lines (2)

AR07.16-D-1080R

2

Counterhold connection of the high-pressure line (3) on high-pressure pump (4) and remove high-pressure line (3)


Do not squeeze or bend high-pressure line (3).
Leaks can occur on the fuel system otherwise.

 Installation: Check sealing cone of high-pressure line (3) for damage and replace if necessary.
Ensure that high-pressure line (3) is seated correctly.

 Nut, pressure line to rail

*BA07.16-N-1016-01A

 Nut, pressure line on high pressure pump

*BA07.16-N-1015-01A

 Socket wrench

*611589000300

 Box wrench bit

*000589680300

3

Seal connections using suitable stop plugs

 Record plug

*129589009100

4

Remove hose (7) on T-piece (12) and close off connections using suitable stop plugs

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

5

Remove screw/bolts (6)

6

Unclip cable duct (8) on the rail (1) and place to one side

7

Release and disconnect electrical connection (9) on fuel pressure sensor (B4/6)

8

Release and disconnect electrical connection (10) on pressure regulating valve (Y74)

9

Remove screw/bolts (11) and remove rail (1)

 Bolt, rail to cylinder head

*BA07.16-N-1007-01A

10

Remove banjo bolt (5) on rail (1) and close off connections with suitable stop plugs

When replacing the rail (1).

 Installation: Replace seals.

 Banjo bolt, leak oil line to rail

*BA07.16-N-1002-01A

 Record plug

*129589009100

11

Install in the reverse order

 Danger !

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

12

Perform engine test run, switch off engine and check fuel system for leaktightness

13

Repeat starting procedure until fuel system is bled and the engine starts


Do not actuate starter for longer than 10 s.
The high-pressure pump (4) will be damaged otherwise.

 Common rail diesel injection (CDI)

Number

Designation

Engine 646.7 in model 909

BA07.16-N-1002-01A

Banjo bolt, leak oil line to rail

Nm

20

 Common rail diesel injection (CDI)

Number

Designation

Engine 646.7 in model 909

BA07.16-N-1007-01A

Bolt, rail to cylinder head

Nm

14

 Common rail diesel injection (CDI)

Number

Designation

Engine 646.7 in model 909

BA07.16-N-1015-01A

Nut, pressure line on high pressure pump

M121.5

Nm

22

 Common rail diesel injection (CDI)

Number

Designation

Engine 646.7 in model 909

BA07.16-N-1016-01A

Nut, pressure line to rail

M151

Nm

27