Remove/install injection lines of common rail direct injection

AR07.16-P-1080FF

Remove/install injection lines of common rail direct injection

23.04.2019

Engine

639.9 in model 454.0

Modification notes

01.12.2005

Fundamental replacement of the high-pressure line and injection lines omitted.

Operation steps 2 and 3

1

Screw

2

High pressure pipe

3

Injection line

 

Remove/install

 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

1

Remove vacuum reservoir

Remove/install vacuum reservoir

AR07.09-P-0001FF

2

Remove screw (1) and remove high-pressure line (2)

Notes about Common-Rail components

AH07.16-P-0002-01TX

 Use suitable stop plugs to seal the openings.
Check sealing cone on the high-pressure line (2); replace in the event of pressure marks on the high-pressure line (2).

 Bolt, pressure line bracket to cylinder head cover

*BA07.16-P-1001-01G

 Nut, pressure line on high pressure pump

*BA07.16-P-1003-01G

 Nut, pressure line to rail

*BA07.16-P-1004-01G

3

Remove injection lines (3)

Notes about Common-Rail components

AH07.16-P-0002-01TX

 Use suitable stop plugs to seal the openings.
Check sealing cone on the injection lines (3); replace in the event of pressure marks on the injection line (3).

 Nut, pressure line to injectors

*BA07.16-P-1002-01G

 Nut, pressure line to rail

*BA07.16-P-1004-01G

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 engine test run and check leak tightness of the fuel system in the area of the injection lines (3) and high-pressure line (2)

 Common rail diesel injection (CDI)

Number

Designation

Engine 639.9

BA07.16-P-1001-01G

Bolt, pressure line bracket to cylinder head cover

Nm

12

 Common rail diesel injection (CDI)

Number

Designation

Engine 639.9

BA07.16-P-1002-01G

Nut, pressure line to injectors

Stage 1

Nm

14

Stage 2

°

60

 Common rail diesel injection (CDI)

Number

Designation

Engine 639.9

BA07.16-P-1003-01G

Nut, pressure line on high pressure pump

Nm

22

 Common rail diesel injection (CDI)

Number

Designation

Engine 639.9

BA07.16-P-1004-01G

Nut, pressure line to rail

Stage 1

Nm

20

Stage 2

°

60