Remove/Install Injection Lines Of Common Rail Direct Injection (CDI) - AR07.16-P-1080OGR

ENGINE 642 in MODEL 166, 292

Shown on the right cylinder head

Courtesy of MERCEDES-BENZ USA

	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
	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 contact with 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
	Notes about Common-Rail components		AH07.16-P-0002-01TX
	Remove/install
1	Remove right or left air filter housing		AR09.10-P-1150OGR
2	Remove engine air intake duct downstream of air filter		AR09.10-P-8130OGR
3	Remove respective soundproofing from left or right cylinder head cover
4	Unclip leak oil line on fuel injectors and place to one side	Do not remove leak oil line.	AR07.03-P-9105OGR
5	Detach bracket of engine wiring harness from left cylinder head cover	Press engine wiring harness to the side in order to allow access to the rear union nut for the injection line (21/6) on the rail.
6	Unscrew union nuts for injection lines (21/6) on the right or left cylinder head	Observe the differing torque specifications. Damage could occur to the fuel injectors or rails otherwise. Use a box wrench bit for the union nuts on the fuel injectors. When working on injection system ensure scrupulous cleanliness! Clean connecting points before opening to protection against contamination. Union nut, pressure line to rail	*BA07.16-P-1028-01C
		Union nut, pressure line to injector	*BA07.16-P-1029-01C
		Box wrench bit	Figure
7	Remove injection lines (21/6)	Close off connections immediately after removal as a protection against contamination using suitable grommets. Do not crush or deform injection lines (21/6). Loosen rail to assemble the injection lines (21/6) free of tension. Only retighten the screw/bolts after all injection lines (21/6) have been attached.	AR07.03-P-1010OGR
7	Remove injection lines (21/6)	Record plug	Figure
8	Remove pressure line between the high-pressure pump and the rail	When removing the injection lines (21/6) on left cylinder head Use a box wrench bit for the union nut on the high-pressure pump. Close off connections immediately after removal as a protection against contamination using suitable grommets. Do not crush or deform pressure line.
		Threaded adapter	Figure
		Fuel line to cylinder head cover/lifting eye/charge air manifold	*BA07.16-P-1022-01C
		Pressure line to high-pressure pump	*BA07.16-P-1025-01C
		Pressure line to high-pressure pump to rail	*BA07.16-P-1026-01C
		Box wrench bit	Figure
		Record plug	Figure
9	Detach left or right rail	If all injection lines (21/6) and the pressure line are loosened, the rail must also be loosened. The injection lines (21/6) and the pressure line must be pushed in by hand up to the end stop. Installation: Only tighten rail after installation of the injection lines (21/6).	AR07.03-P-1010OGR
	Check
10	Check sealing cone for injection lines (21/6) and the pressure line on the high-pressure pump and rail on pressure marks	If pressure marks are found, replace the respective injection line (21/6) and pressure line. For pressure marks on the injection lines (21/6): ↓ Replace pressure line.
11	Install in the reverse order
12	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. Check fuel system for leaks with engine 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