Remove/install injection lines of common rail direct injection

AR07.16-P-1080MFE

Remove/install injection lines of common rail direct injection

20.08.2019

Engine

608 in model 118, 177, 247

1

Injection lines

3

Injection line

2

Rail

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Remove cylinder head cover trim.

AR01.20-P-5015MFE

 Installation: Only install upper engine cover after the leak test.

2

Disconnect ground line of on-board electrical system battery (G1).

AR54.10-P-0003MFA

3

Release low-pressure lines and place to one side.

AR07.03-P-0120MFE

4

Release injection lines (1) from injectors and from the rail (2) and unscrew union nuts.


Ensure utmost cleanliness. Do not squeeze or bend injection lines (1).
Leaks and damage will occur otherwise.

 Installation: Replace injection lines (1).
First, tighten union nuts of the injection lines (1) slightly by hand, then, tighten at the rail (2), and finally, tighten at the fuel injectors.

 Union nut, pressure line to injector/ rail

*BA07.16-P-1006-01K

 Box wrench bit

*000589680300

5

Remove the injection lines (1) and catch escaping fuel with suitable rags.

 Use only lint-free rags.

6

Seal exposed connections using suitable plugs.

 Record plug

*129589009100

7

Release injection line (3) from the high-pressure pump and from the rail (2) and unscrew union nuts.


Ensure utmost cleanliness. Do not crush or bend injection line (3).
Leaks and damage will occur otherwise.

 Installation: Replace injection line (3).
First, tighten the union nuts of the injection line (3) slightly by hand, then, tighten at the rail (2), and, finally, at the high-pressure pump.

 Union nut, pressure line to high-pressure pump/rail

*BA07.16-P-1005-01K

 Box wrench bit

*000589690300

 Box wrench bit

*000589680300

8

Remove injection line (3) and catch escaping fuel with suitable rags.

 Use only lint-free rags.

9

Seal exposed connections using suitable plugs.

 Record plug

*129589009100

10

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

11

Perform engine test run thus checking function and leak tightness.

12

Install upper engine cover.



AP01.10-P-2405-01B

 Common rail diesel injection (CDI)

Number

Designation

Engine 608

BA07.16-P-1005-01K

Union nut, pressure line to high-pressure pump/rail

M12

Nm

28

 Common rail diesel injection (CDI)

Number

Designation

Engine 608

BA07.16-P-1006-01K

Union nut, pressure line to injector/ rail

M12

Nm

28