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

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

Engine Series 104 

Fig 1: Identifying O-Rings, Fuel Rail, Fuel Return Flow Line And Injectors

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Using Engine 111.940 for illustration purposes 

Fig 2: Identifying Service Valve, O-Rings, Fuel Rail, Fuel Return Flow Line And Injectors

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Removing, installing
	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	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).
			Fig 6
			Fig 7
3.1	Remove the oil filter.	Only engine 104 with integrated oil-water cooler
			Fig 4
4	Remove the fuel rail (17).	Installation:  Replace O-rings (16/8), oil to facilitate installation
		Engine 104	*BA09.20-P-1001-01B
		Engine 111	*BA07.52-P-1001-01B
5	Unscrew the fuel supply line (17/3).	Catch emerging fuel in a suitable container.
6.1	Unbolt fuel return flow line (17/2)	Except engine 111.977 Catch emerging fuel in a suitable container.
7	Reverse the removal sequence to install.

Intake manifold

Fuel rail

Fig 3: Identifying Tester (103 589 00 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Socket Attachment (103 589 02 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Pressure House (119 589 04 63 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Tester (103 589 00 2100)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying Pressure hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.