Remove/install injection lines of common rail diesel injection (CDI) - AR07.16-P-1080GZB

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ENGINE 642 in MODEL 164, 251

Fig 1: Identifying Common Rail Diesel Injection Line Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	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
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof.	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
1	Remove air filter housing	Left side:
		Model 164	AR09.10-P-1150GZB
		Model 251	AR09.10-P-1150RTB
		Right side:
		Model 164	AR09.10-P-1150GZC
		Model 251	AR09.10-P-1150RTC
2	Remove engine intake air duct downstream of air filter		AR09.10-P-8130GZB
3	Remove leak oil line (3) at injectors	Pull fuse (2) upwards and remove leak oil line (3). Installation: Push securing device (2) downwards until it engages audibly.	AR07.03-P-9105A
4	Unscrew bolt (4)
5	Unscrew bracket on engine wiring harness
6	Unscrew union nuts (5) on injection lines (21/6)	Pay attention to different tightening torques otherwise injectors or rail (21) could be damaged. When working on injection system ensure scrupulous cleanliness! Clean separation points before opening.
			*BA07.16-P-1028-01C
			*BA07.16-P-1029-01C
		Box wrench bit	Figure
7	Remove injection lines (21/6)	Close all connections of the injection lines (21/6) to prevent contamination immediately after removal. Do not crush or deform injection lines (21/6). Installation: Loosen rail (21) to assemble injection lines (21/6) free of tension. Only retighten bolts after all injection lines (21/6) have been attached: ↓
		See Remove/install rail.	AR07.03-P-1010GZB
		Set of stop plugs	Figure
8	Remove bracket	To do this, unscrew bolt (6).
9	Loosen rail (21)	Installation: If all injection lines (21/6) are released, loosen rail (21) and push in injection lines (21/6) by hand all the way.
10	Remove compressed air line (19/1)	Close all connections of pressure lines (19/1) immediately after removal as a protection against contamination. Do not crush or deform pressure line (19/1).
			*BA07.16-P-1025-01C
			*BA07.16-P-1026-01C
			Figure
			Figure
	Checking
11	Inspect taper gasket of injection lines (21/6) and pressure line (19/1)	Installation: If there are visible pressure marks on injection lines (21/6) or the pressure line (19/1) then these must be replaced.
12	Install in the reverse order
	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
13	Check fuel system for leaks with engine running

COMMON RAIL DIESEL INJECTION (CDI)

Number	Designation			Engine 642
BA07.16-P-1025-01C	Pressure line on high-pressure pump	M14	Nm	33
BA07.16-P-1026-01C	Pressure line to high-pressure pump to rail	M15	Nm	27
BA07.16-P-1028-01C	Pressure line union nut to rail	M15	Nm	27
BA07.16-P-1029-01C	Pressure line union nut to injector	M14	Nm	33

Fig 2: Identifying Box Wrench Bit (000 589 68 03 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.