Remove/install injection lines of common rail direct injection

AR07.16-P-1080OLD

Remove/install injection lines of common rail direct injection

04.09.2018

Engine

651 in model 205, 253

Shown on ENGINE 651.924

7

Electrical connections

B6/1

Camshaft Hall sensor

8

Cable duct

Y76

Fuel injectors

9

Injection lines

10

Bracket

15

High-pressure pump

11

Mounting plate

16

Rail

12

High-pressure line

17

High-pressure fitting

13

Screw/bolt

Y85

Exhaust gas recirculation cooler bypass switchover valve

14

Screw/bolt

 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

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove engine cover

2

Press together the securing bracket and disconnect of the electrical connections (7)

When removing the injection lines (9).

 Installation: Replace sealing rings and housing cover on electrical connections (7).

3

Unclip cable duct (8) from injection lines (9) upwards and place to one side

When removing the injection lines (9).

4

Unscrew union nuts for injection lines (9)

When removing the injection lines (9).

 Installation:
Always replace injection lines (9). Ensure utmost cleanliness. Do not crush or bend injection lines (9).
Leaks and damage nay occur otherwise.


Counterhold connections for injection lines (9).
Otherwise damage may occur.

 Installation:
When mounting the injection lines (9) for cylinder 3 and 4 the markings must be located at the side of the rail.
Leaks can occur otherwise.

 Plug connections on rail and fuel injectors (Y76). Grommets are available as an replacement part of the fuel injection system; see EPC Group 07.
Repeated usage of stop plugs is not allowed.

 Installation: Tighten union nut on fuel injectors (Y76) finger-tight. Only tighten union nuts on fuel injectors (Y76) after tightening the union nuts on the rail (16).

 Union nut, pressure line to injector/ rail

*BA07.16-P-1009-01H

 Box wrench bit

*000589690300

5

Remove exhaust gas recirculation valve

When removing high pressure line (12).

AR14.20-P-7662OLD

6

Remove screw/bolts (13, 14) on high-pressure line (12) bracket

When removing high-pressure line (12).

7

Detach exhaust gas recirculation cooler bypass switchover valve (Y85) with attached lines from holder (10) and place to one side

When removing high-pressure line (12).

8

Remove bracket (10)

When removing high-pressure line (12).

 Bolt, bracket for electric switchover valves to fastening plate

*BA09.41-P-1006-01N

9

Remove mounting plate (11)

When removing high-pressure line (12).

 Charge air manifold fastening plate bolt on engine support

*BA09.41-P-1005-01N

10

Unscrew union nuts and remove high-pressure line (12) from high-pressure pump (15) and rail (16)

When removing high pressure line (12).

 Close off connections on rail (16), high-pressure pump (15) and high-pressure line (12). Grommets are available as an replacement part of the fuel injection system; see EPC Group 07.
Repeated usage of stop plugs is not allowed.

 Counterhold high-pressure fitting (17) to avoid it from loosing as the high pressure line is being loosened. After disassembly, close off the high-pressure line (12) connections. Ensure scrupulous cleanliness!

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

*BA07.16-P-1002-01H

 Box wrench bit

*000589690300

11

Check sealing cone on the high-pressure line (12)

When removing high-pressure line (12).

 Installation: Install high-pressure line (12) free of tension.

For damage



Replace high-pressure line (12)

12

Clean high-pressure pump (15) in the area of high-pressure fitting (17) and blow dry with compressed air

When removing high-pressure line (12).

 Use absorbent, lint-free cloth to collect escaping fuel that runs out.

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

*BR00.45-Z-1051-04A

13

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

14

Check leaktightness of fuel injection system with engine running

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1002-01H

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

Nm

33

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1009-01H

Union nut, pressure line to injector/ rail

Nm

33

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1005-01N

Charge air manifold fastening plate bolt on engine support

Nm

20

 Charge air pipe/charge air cooling

Number

Designation

Engine 651

BA09.41-P-1006-01N

Bolt, bracket for electric switchover valves to fastening plate

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1051-04A

Cold degreasing agent/cold cleaning solvent HAKU 1025-920

Chemische Werke Kluthe GmbH
Gottlieb-Daimler-Str. 12
69115 Heidelberg
Germany
Tel. +49 6221 5301-0
Fax +49 6221 5301-176
http://kluthe.com