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Removing and installing fuel rail with injection valves - AR07.03-P-1450D

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ENGINE 104.94 /99, 111.920 /921 /94 /96 /970 /973 /974 /975 /977 (except, 104.990) 

Engine Series 104 

Fig 1: Identifying Fuel Rail With Injection Valves Components - Engine Series 104
G04713230Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Using Engine 111.940 for illustration purposes 

Fig 2: Identifying Fuel Rail With Injection Valves Components - Engine 111.940
G04713231Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Removing, installing     
DANGER Risk of explosion  from ignition, risk of poisoning  from inhaling and swallowing fuel as well as risk of injury  from skin and eye contact with fuel. No fire, sparks, naked flames or smoking. Pour fuels only into suitable and appropriately marked containers.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A
1.1 Remove air filter cross pipe IMPORTANT Except engine 111.943/947/973/975 AR09.10-P-8031G
2 Use service valve (1/1) to bleed pressure from the fuel rail (17). SPECIAL TOOL Fig 3
    SPECIAL TOOL Fig 5
3.1 Remove the oil filter. IMPORTANT Only engine 104 with integrated oil-water cooler  
    SPECIAL TOOL Fig 4
4 Remove the fuel rail (17). IMPORTANTInstallation:  Replace O-rings (16/8), oil to facilitate installation
TORQUE SPECIFICATION Engine 104		 *BA09.20-P-1001-01B 
    TORQUE SPECIFICATION Engine 111 *BA07.52-P-1001-01B 
5 Unscrew the fuel supply line (17/3). IMPORTANT Catch emerging fuel in a suitable container.  
6.1 Unbolt fuel return flow line (17/2) IMPORTANT Except engine 111.977
Catch emerging fuel in a suitable container.		  
7 Reverse the removal sequence to install.    
TORQUE SPECIFICATION INTAKE MANIFOLD

Number Designation Engine 104
BA09.20-P-1001-01B Bolts and nuts of intake manifold to cylinder head Nm 25
TORQUE SPECIFICATION FUEL RAIL

Number Designation Engine 111.92/94/951/952/955/956/957/96/97/981/982 Engine 111.958/983
BA07.52-P-1001-01B Bolt of fuel rail to cylinder head Nm 25 25
BA07.52-P-1002-01B Fuel feed line to fuel rail Nm 24 24
Fig 3: Identifying Tester (103 589 00 21 00)
G04713232Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Socket Attachment (103 589 02 09 00)
G04713233Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Pressure Hose (119 589 04 63 00)
G04713234Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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