1 | Rail |
2 | High pressure pipe |
3 | Electrical connector |
4 | Bolts |
5 | Return hose |
6 | Screw |
7 | Screw |
8 | High pressure pipe |
S07.03-4558-76
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. | |
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. | |
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | ||
Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | |||
Notes about Common-Rail components | |||
| Remove/install | ||
1 | Remove charge air pipe downstream of exhaust gas turbocharger. | ||
Installation: Only install upper engine cover after the leak test. | |||
2 | Remove upper section of left air filter housing. | ||
| Replace air filter element | ||
3 | Disconnect electrical connector (3). | ||
4 | Remove screws/bolts (4). | Bolt, high-pressure line retaining clamp to cylinder head cover/charge-air distributor | |
5 | Remove union nut of high-pressure line (2) at rail (1). | Union nut, rail high-pressure line to rail | |
Open double hexagon box wrench | |||
6 | Remove screw (7). | Bolt, high-pressure line retaining clamp to cylinder head cover/charge-air distributor | |
7 | Remove high-pressure line (8) from rail (1). | Union nut, high-pressure line for fuel system high pressure pump to rail | |
Open double hexagon box wrench | |||
8 | Remove injection lines at rail (1). | ||
Installation: Also position high-pressure lines (2, 8) during attachment of injection lines so that they are free of tension and slightly tighten their union nut by hand. | |||
9 | Remove rail (1). | | |
To do so, remove the screw/bolts (6). Remove return hose (5) from rail (1). Plug openings. | |||
Installation: Replace snap clamp. Do not yet screw in screws (6). | |||
Record plug | |||
Pliers for click clamps | |||
| Check | ||
10 | Check sealing cone of high-pressure lines (2) for pressure marks. | If pressure marks exist | |
| |||
Replace high-pressure line(2). | |||
Union nut, rail high-pressure line to rail | |||
Open double hexagon box wrench | |||
11 | Check sealing cone of high-pressure line (8) for pressure marks. | If pressure marks exist | |
| |||
Replace high-pressure line(8). | |||
12 | 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. | |
13 | Check fuel system for leaks with engine running. | Visual inspection only. |
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Open double hexagon box wrench
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Record plug
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Pliers for click clamps