Remove/install injection lines of common rail direct injection

AR07.16-D-1080R

Remove/install injection lines of common rail direct injection

10.10.2017

Engine

646 in model 909

1

Injection lines

 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 cylinder head cover trim

AR01.20-D-5014-02R

 Installation: Only install cylinder head cover trim panel after the leak test.

 Bolt, trim panel to cylinder head cover

*BA01.20-N-1003-01M

2

Unscrew union nuts for injection lines (1)


Counterhold the threaded sleeve of the injectors using a suitable tool.
Damage will occur to the injectors otherwise.



 Nut, pressure line to rail

*BA07.16-N-1016-01A

 Nut, pressure line to piezo injector

*BA07.16-N-1017-01A

 Box wrench bit

*000589680300

3

Remove injection line (1)


After disassembly of injection lines (1), seal connections of rail and injectors. Ensure utmost cleanliness.
Leakage will occur on the injection system otherwise.

 Installation: Replace injection lines (1). Pay attention to exact seating of injection lines (1).

 Record plug

*129589009100

4

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

5

Perform an engine test run, stop engine and check fuel system for leakage in area of injection lines (1)

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 646 in model 909

BA01.20-N-1003-01M

Bolt, trim panel to cylinder head cover

Nm

10

 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

 Common rail diesel injection (CDI)

Number

Designation

Engine 646.7 in model 909

BA07.16-N-1017-01A

Nut, pressure line to piezo injector

M141.5

Nm

33