Remove/install high-pressure line to rail

AR07.16-S-1004PS

Remove/install high-pressure line to rail

28.06.2019

Engine

642 in model 470, 471

1

High pressure pipe

2

Screw

3

Cable duct

4

High-pressure fitting

 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

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

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

1

Remove clean air line.

AR09.10-S-8140PS

2

Attach union nut of high-pressure line (1) to rail.

 Open double hexagon box wrench

*454589000300

3

Remove screw/bolt (2).

4

Detach cable duct (3).

 Slightly lift cable duct (3) (arrows).

5

Attach union nut of high-pressure line (1) to high-pressure pump.

 Counterhold high-pressure fitting of high-pressure pump (4) using a suitable tool.

 Box wrench bit

*000589680300

6

Remove the high-pressure line (1).


Do not crush or deform high-pressure line (1).
Leaks and damage will occur otherwise.

 Seal connections at rail and high-pressure pump.

 Record plug

*129589009100

7

Remove high-pressure fitting (4).

If the high-pressure fitting (4) is loose or leaky.



Check

8

Check sealing cones of high-pressure line (1) for pressure marks.

If pressure mark are visible:



Replace high-pressure line (1).



Install

9

Screw the high-pressure fitting (4) in again.

If loose or leaky high-pressure fitting (4) has been removed.

 Replace sealing ring.

 Fitting on fuel system high pressure pump

*BA07.16-N-1010-03PS

10

Install high-pressure line (1).


Do not crush or deform high-pressure line (1).
Leaks and damage will occur otherwise.

 Position the high-pressure line (1) so it is free of tension, and slightly tighten union nuts on high-pressure pump and rail by hand.

11

Tighten union nut of high-pressure line (1) on rail.

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

AH00.00-P-0015-01CW

 Union nut, high-pressure line for fuel system high pressure pump to rail

*BA07.16-N-1007-03PS

 Open double hexagon box wrench

*454589000300

12

Tighten union nut of high-pressure line (1) on high-pressure pump.

 Counterhold high-pressure fitting (4) of high-pressure pump (1) using a suitable tool.

 Union nut, high-pressure line for fuel system high pressure pump to fuel system high pressure pump

*BA07.16-N-1008-03PS

 Box wrench bit

*000589680300

13

Attach cable duct (3).

14

Screw in bolt (2).

 Bolt, high-pressure line retaining clamp to cylinder head cover/charge-air distributor

*BA07.16-N-1013-03PS

15

Install clean air line.

AR09.10-S-8140PS

 Do not install the top engine cover yet.



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

16

Check fuel system for leaks with engine running.

 Visual inspection only.

17

Install upper engine cover.

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1007-03PS

Union nut, high-pressure line for fuel system high pressure pump to rail

Stage 1

Nm

20

Stage 2

°

60

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1008-03PS

Union nut, high-pressure line for fuel system high pressure pump to fuel system high pressure pump

Stage 1

Nm

20

Stage 2

°

60

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1010-03PS

Fitting on fuel system high pressure pump

Nm

55

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1013-03PS

Bolt, high-pressure line retaining clamp to cylinder head cover/charge-air distributor

Nm

9