S07.16-2518-12
1 Cylinder head cover trim panel
2 Rail
3 Injection line
4 Bracket
5 High pressure line
6 Fuel return flow line high pressure pump-rail
7 Fuel return line
8 Sealing ring
9 Leak oil line
10 Intake manifold
11 Bolt
12 Connector
B66 Rail pressure sensor
Y74 Pressure control valve
| Remove/install | ||
1 | Disconnect ground line of battery | ||
2 | Remove mixing housing with exhaust gas recirculation | ||
3 | Remove trim panel of cylinder head cover (1) | ||
4 | Disconnect electrical connector on rail pressure sensor (B66) | Expose cables. | |
5 | Disconnect electrical connector on pressure regulating valve (Y74) | Expose cables. | |
Danger! | Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel. | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
6 | Remove injection line (3) | ||
7 | Remove holder (4) of pressure line (5) on coolant temperature control | External torx set | |
8 | Unbolt pressure line (5) on rail (2) | Use a wrench to counterhold when slackening the union nut. On no account exceed tightening torque. This will prevent the threaded connection from being slackened when the line is unscrewed again. Do not crimp or bend line. Ensure scrupulous cleanliness. | |
Catch escaping fuel. | |||
| |||
9 | Remove fuel return line to high-pressure pump (6) on rail (2) | Observe handling of the loosening clamp in order to avoid damage. | |
10 | Detach fuel return flow line (7) at rail (2) | Remove for replacing the rail connector (12) and replace sealing rings (8). | |
| |||
11 | Detach leak oil line (9) on rail (2) | ||
12 | Expose fuel lines on intake manifold (19) | ||
13 | Remove rail (2) to the left | In order to remove fuel leaks, the pressure regulating valve (Y74) must not be separated or removed from the rail up to VIN 207'600. | |
From VIN 207'601 the pressure regulating valve (Y74) can be removed. Refer to: | |||
Remove/install pressure control valve | |||
When renewing the rail: new rail (2) is delivered with rail pressure sensor (B66) and pressure regulating valve (Y74). | |||
Installation: Only tighten rail (2) after feeding in all the screw lines (3, 5). | |||
| |||
External Torx set | |||
14 | Install in the reverse order | ||
| Checking | ||
Danger! | Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running | Secure vehicle to prevent it from moving by itself. | |
15 | Ventilate fuel system | ||
16 | Inspect fuel system for leaks | Run engine, switch off and inspect for leaks. | |
17 | Read out fault memory and erase | Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed. Refer to: | |
Diagnosis manual for diesel engine, Volume 1.2 |
Common rail diesel injection (CDI)
Number | Designation | Engine 611.980 | |||
BA07.16-P-1002-01A | Nut, pressure line to high-pressure pump/rail | Nm | 23 | ||
BA07.16-P-1004-01A | Bolt, rail to cylinder head | Nm | 14 | ||
BA07.16-P-1006-01A | Banjo bolt, leak oil line to rail | Nm | 20 | ||
External Torx set
001 589 76 09 00
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