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Remove/install rail - AR07.03-P-1010TI

ENGINES 642 in MODEL 211 

Fig 1: Identifying Rail Components
G07248955Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install     
DANGER Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.		 AS00.00-Z-0005-01A
DANGER Risk of explosion  from 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 systems when they are under pressure AS07.16-Z-0001-01A 
DANGER Risk of explosion  caused by ignition of flammable products, risk of poisoning  caused by inhaling fuel vapors or swallowing fuel as well as risk of injury  to skin and eyes exposed to fuel. No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A
1 Remove injection lines   AR07.16-P-1080TI 
2 Disconnect electrical connectors from rail pressure sensor (B4/6)    
3 Disconnect electrical connectors from pressure regulator valve (Y74)    
4 Disconnect return line (2)    
5 Unscrew union nuts (3) on pressure lines (19/1) IMPORTANT When loosening union nuts (3), counterhold connection fittings for pressure lines (19/1).
IMPORTANTInstallation:  When tightening union nuts (3), counterhold connection fittings for pressure lines (19/1).		  
TORQUE SPECIFICATION Pressure line to high-pressure pump *BA07.16-P-1025-01C 
TORQUE SPECIFICATION Pressure line of high pressure pump to rail *BA07.16-P-1026-01C 
SPECIAL TOOL Box wrench bit Fig 2
6 Remove pressure lines (19/1) IMPORTANT Close connections of pressure lines (19/1) immediately after removal as a protection against contamination. Do not crush or deform pressure lines (19/1).  
SPECIAL TOOL Set of stop plugs Figure
7 Unscrew union nuts (3) on connecting line (19/2) IMPORTANT Close connections of connecting line (19/2) immediately after removal as a protection against contamination. Do not crush or deform connecting line (19/2).  
TORQUE SPECIFICATION Connecting line between left and right rail *BA07.16-P-1024-01C 
SPECIAL TOOL Set of stop plugs Figure
SPECIAL TOOL Box wrench bit Fig 2
INSPECT Checking     
8 Inspect taper gasket of pressure line (19/1) IMPORTANTInstallation:  If pressure marks, replace pressure line (19/1).  
9 Inspect taper gasket of connecting line (19/2) IMPORTANTInstallation:  If pressure marks, replace connecting line (19/2).  
10 Remove bolt (1) TORQUE SPECIFICATION *BA07.16-P-1003-01C 
11 Remove rails (21) IMPORTANTInstallation:  Finger-tighten union nuts (3) of connecting line (19/2) and pressure line (19/1) and then tighten bolts (1).  
12 Install in the reverse order    
13 Check fuel system for leaks with engine running    
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation Engine 642
BA07.16-P-1003-01C Bolt, rail to cylinder head Nm 14
BA07.16-P-1024-01C Connecting line between left and right rail M15 Nm 27
BA07.16-P-1025-01C Pressure line to high-pressure pump M14 Nm 33
BA07.16-P-1026-01C Pressure line to high-pressure pump to rail M15 Nm 27
Fig 2: Identifying Box Wrench Bit (000 589 68 03 00)
G07248956Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Set Of Stop Plugs (129 589 00 91 00)
G07248957Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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