Incorrect refueling of diesel vehicles with a common rail injection system:
Please observe that refueling with incorrect fuel is the fault of the customer and cannot be invoiced through the warranty channels.
When a vehicle with common-rail injection system has been refueled with spark-ignition engine fuel (gasoline) or AdBlue®, proceed as follows:
Warning | Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof. | No parts of the body or limbs should be within the operating area when the components are moving. | |
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. | |
Notes about Common-Rail components | Engine 607, 628, 629, 642, 646.9, 651, 654, 656 | ||
| Check | ||
1 | Check if the engine was started since incorrect fueling took place | If the engine was not yet started after refueling with incorrect fuel, | |
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Proceed with operation step 2. | |||
On engine 611, 612, 613, 660, 668 | |||
continue with operation step 3. | |||
For engine 607, 626, 628, 629, 639, 640, 642, 646, 647, 648, 651, 654, 656 | |||
If the engine was started since incorrect fueling took place, | |||
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Continue with operation step 6. | |||
On engine 611, 612, 613, 668 | |||
Proceed with operation step 7.1. | |||
With engine 628, 629, 639, 640, 642, 646, 647, 648, 660 | |||
Proceed with operation step 7.2. | |||
With engine 607, 626, 651 | |||
Remove/install after incorrect refueling without engine start | |||
2 | Drain fuel tank completely | Engine 611, 612, 613, 660, 668 | |
If the fuel tank has been properly drained. | |||
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Proceed with operation step 4. | |||
3 | Pump out fuel | Engine 607, 626, 628, 629, 639, 640, 642, 646, 647, 648, 651, 654, 656 | |
The fuel must be emptied or pumped out through the fuel feed module opening. Make sure that the swirl pot is completely emptied too. | |||
4 | Clean low-pressure lines | ||
5 | Fill the tank with fuel | ||
Remove/install after incorrect refueling with spark-ignition engine fuel with engine start | |||
6 | Check rail connection for shavings | Engine 611, 612, 613, 668 | |
Open the low-pressure connection for the fuel return from the fuel system high pressure pump (plastic connection in area of pressure regulating valve (Y74)) on the rail and check the connection of the rail for shavings. | |||
If there are no shavings found in the diesel injection system, | |||
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Proceed with operation step 10. | |||
If there are shavings in the diesel injection system, | |||
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Proceed with operation step 16. | |||
7.1 | Detach Yshaped distributor from output | Engine 628, 629, 639, 640, 642, 646, 647, 648, 660 | |
The Yshaped distributor is located om the return flow fuel system high pressure pump/rail. | |||
7.2 | Disconnect return line from rail output | Engine 607, 626, 651, 654, 656 | |
8 | Ignition ON and collect the escaping fuel in a clean vessel | Engine 607, 628, 629, 639, 640, 642, 646, 647, 648, 651, 654, 656, 660 | |
9 | Check collected fuel collected for signs of shavings | Engine 607, 626, 628, 629, 639, 640, 642, 646, 647, 648, 651, 654, 656, 660 | |
If there are no shavings found in the diesel injection system or in the fuel, | |||
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Continue with step 11 or 12. | |||
If there are shavings in the diesel injection system or in the fuel, | |||
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Proceed with operation step 16. | |||
10 | Drain fuel tank | Engine 611, 612, 613, 660, 668 | |
11 | Pump out fuel | Engine 607, 626, 628, 629, 639, 640, 642, 646, 647, 648, 651, 654, 656 | |
The fuel must be emptied or pumped out through the fuel feed module opening. Note that the swirl pot must be completely emptied too. | |||
12 | Clean low-pressure lines | ||
13 | Replace fuel filter | ||
14 | Fill the tank with fuel | ||
15 | Check diesel particulate filter for damage | Check diesel particulate filter, if fitted, for signs of thermal damage and replace, if necessary. | |
16 | Replace parts of fuel system | If shavings are found in the fuel system or damage to the fuel high-pressure pump drive. | |
Replace the following components: | |||
Remove/install after incorrect refueling with AdBlue® with engine start | |||
17 | Drain fuel tank | ||
18 | Replace parts of fuel system | If shavings are found in the fuel system or damage to the fuel high-pressure pump drive. | |
Replace the following components: |