1 | High pressure pipe |
2 | Screw |
3 | Cable duct |
4 | High-pressure fitting |
S07.16-A040-76
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. | |
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. | |
Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Notes about Common-Rail components | |||
| Remove | ||
1 | Remove clean air line. | ||
2 | Attach union nut of high-pressure line (1) to rail. | Open double hexagon box wrench | |
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 | |||
6 | Remove the high-pressure line (1). | | |
Seal connections at rail and high-pressure pump. | |||
Record plug | |||
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 | |||
10 | Install high-pressure line (1). | | |
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 | |||
Union nut, high-pressure line for fuel system high pressure pump to rail | |||
Open double hexagon box wrench | |||
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 | |||
Box wrench bit | |||
13 | Attach cable duct (3). | ||
14 | Screw in bolt (2). | Bolt, high-pressure line retaining clamp to cylinder head cover/charge-air distributor | |
15 | Install clean air line. | ||
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. | |
16 | Check fuel system for leaks with engine running. | Visual inspection only. | |
17 | Install upper engine cover. |
000 589 68 03 00
Box wrench bit
129 589 00 91 00
Record plug
454 589 00 03 00
Open double hexagon box wrench