Remove/install injection lines of common rail direct injection

AR07.16-S-1080EA

Remove/install injection lines of common rail direct injection

07.07.2020

Engine

654.9 in model 447

Modification notes

23.10.2019

Union nut, pressure line to rail

BA07.16-P-1002-04A

27.11.2019

Union nut, pressure line to rail

BA07.16-P-1002-04A

27.11.2019

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

BA07.16-P-1003-04A

1

Bolts

5

Cable duct

8

Bolts

2

Boost pressure sensor holder

6

Electrical connectors

9

Bracket

3

Soundproofing

7

Electrical wiring harness

10

Injection lines

4

Oil separator

 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

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

 

Remove/install

1

Remove air filter housing.

AR09.10-S-1150EA

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

2

Remove the screws (1) and place the boost pressure sensor holder (2) to one side.

 Screw, boost pressure sensor holder to cylinder head cover

*BA01.20-N-1003-03EA

3

Unclip the cable duct (5) on the oil separator (4).

4

Remove soundproofing(3).

5

Release and disconnect electrical connectors (6).

6

Unclip the electrical wiring harness (7) on the injection lines (10) and place to one side.

7

Unscrew the bolts (8) and remove the bracket (9).

 Bolt, bracket for engine cover to cylinder head cover

*BA01.20-N-1002-03EA

8

Unscrew the union nuts of the injection lines (10).

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

AH00.00-P-0015-01CW

 Installation: First, slightly tighten union nuts of injection lines (10) by hand, then tighten at rail, and finally at fuel injectors.

 Union nut, pressure line to rail

*BA07.16-P-1002-04A

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

*BA07.16-P-1003-04A

 Open double hexagon box wrench

*454589000300

 Box wrench bit

*000589680300

9

Remove the injection lines (10) and collect any escaping fuel with a dry cloth.

 Installation: Install new injection lines (10).

10

Seal connections on rail and fuel injectors with stop plugs.


Ensure utmost cleanliness.
Otherwise, leaks and malfunctions occur.

 Record plug

*129589009100

11

Install in the reverse order.



Check

 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

12

Perform an engine test run; check the fuel injection system for leaks.

13

Install upper engine cover.

AR01.10-S-2405EA

 Cylinder head cover

Number

Designation

Engine 654.9 in model 447

BA01.20-N-1002-03EA

Bolt, bracket for engine cover to cylinder head cover

Nm

9

 Cylinder head cover

Number

Designation

Engine 654.9 in model 447

BA01.20-N-1003-03EA

Screw, boost pressure sensor holder to cylinder head cover

Nm

6

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1002-04A

Union nut, pressure line to rail

Nm

27

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1003-04A

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

Nm

33