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

ENGINES 651 in MODELS 166, 172, 204, 207, 212, 218, 221 

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	Remove/install
	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
	Notes about Common-Rail components		AH07.16-P-0002-01TX
1	Remove cylinder head cover trim
2	Remove section for partition wall on the left and the center	Model 166
	Remove injection line (9)
3	Disconnect electrical connectors (7)
4	Unclip wiring shaft (8) from injection lines (9) upwards and place to one side.
5	Unscrew union nuts for injection lines (9)	In the process counterhold all connections for the injection lines (9). Material breakages can occur otherwise.	*BA07.16-P-1009-01H
		Box wrench bit	Figure
6	Remove injector lines (9)	All connectors must be closed off after disassembly of the injection lines. Damage can occur to the high pressure components otherwise. Stop plugs are available as a replacement part for the injection system. Multiple use of the stop plug is not permitted. Ensure scrupulous cleanliness! Installation:  Always replace injection lines (9) and install unstressed. During assembly of the injection lines (9) for cylinders 3 and 4 ensure that the marking is on the side of the rail (5) since leaks can occur otherwise.
	Remove high pressure line (1)
7	Remove exhaust gas recirculation valve	Model 204, 207, 212, 218, 221	AR14.20-P-7662CD
		Model 166, 172	AR14.20-P-7662GQ
8	Remove screw/bolts (2, 3) on high-pressure line (1) bracket
9	Unscrew and remove high pressure line (1) from the high pressure pump (4) and rail (5)	Counterhold high pressure fitting (6) to avoid it from coming loose as the high pressure line is being loosened. After disassembly, close off the high pressure line (1) connections. Ensure scrupulous cleanliness! All connectors must be closed off after disassembly of the injection lines. Damage can occur to the high pressure components otherwise. Stop plugs are available as a replacement part for the injection system. Multiple use of the stop plug is not permitted. Ensure scrupulous cleanliness! Installation:  Install high-pressure line (1) free of tension.	*BA07.16-P-1002-01H
		Box wrench bit	Figure
10	Clean high pressure pump (4) in the area of high pressure fitting (6) with cold cleaning solvent and blow dry with compressed air	Depending on installation position, use an absorbent, lint-free cloth to collect any fuel that runs out. Cold degreasing agent/cold cleaning solvent HAKU 1025-920	*BR00.45-Z-1051-04A
11	Install in the reverse order
12	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 Check fuel system for leaks with engine 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

Common rail diesel injection (CDI)

Number	Designation		Engine 651
BA07.16-P-1002-01H	Union nut, pressure line to high-pressure pump/rail	Nm	33
BA07.16-P-1009-01H	Pressure line union nut on injector/rail	Nm	33

Fig 1: Identifying Box Wrench Bit (000 589 69 03 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1051-04A	Cold degreasing agent/cold cleaning solvent HAKU 1025-920	Chemische Werke Kluthe GmbH