Remove/install rail

AR07.03-P-1010GP

Remove/install rail

31.05.2019

Engine

642 in model 461

1

Screw

3

Union nuts

19/2

Fuel line

21

Rails

B4/6

High-pressure fuel pressure sensor

Y74

Pressure regulator valve

2

Return flow pipe

19/1

Pressure line

 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

 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/install

1

Remove injection lines.

AR07.16-P-1080GY

2

Release and disconnect electrical connectors at high-pressure fuel pressure sensor (B4/6).

3

Release and disconnect electrical connectors at pressure regulating valve (Y74).

4

Remove return line (2) from left rail (21).

5

Unscrew union nuts (3) of pressure line (19/1).


Do not crush or deform pressure line (19/1).
Leaks or damage can occur otherwise.

 Counterhold connection fittings of pressure line (19/1) when releasing union nuts (3).

 Installation: Counterhold connection fittings of pressure line (19/1) when tightening union nuts (3).

 Pressure line to high-pressure pump to rail

*BA07.16-P-1026-01C

 Pressure line to high-pressure pump

*BA07.16-P-1025-01C

 Tool kit

*000589109900

6

Unscrew union nuts (3) of fuel line (19/2) and seal openings with suitable stop plugs.


Do not crush or deform fuel line (19/2).
Leaks or damage can occur otherwise.

 Counterhold connection fittings of fuel line (19/2) when releasing union nuts (3).

 Installation: Counterhold connection fittings of fuel line (19/2) when tightening union nuts (3).

 Fuel line between left and right tail

*BA07.16-P-1024-01C

 Tool kit

*000589109900

 Record plug

*129589009100

7

Remove bolts (1).

 Bolt, rail to cylinder head

*BA07.16-P-1003-01C

8

Remove rails (21).

 Installation: Install union nuts (3) so that finger-tight and then finger-tighten bolts (1).



Check

9

Check sealing cones at pressure line (19/1).

If there are problems,



Replace pressure line (19/1).

10

Check sealing cones at fuel line (19/2).

If there are problems,



Replace fuel line (19/2).

11

Install in the reverse order.

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1003-01C

Bolt, rail to cylinder head

Nm

14

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1024-01C

Fuel line between left and right tail

M15

Nm

27

 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