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Remove/install rail - AR07.03-P-1010GZB

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ENGINE 642 in MODEL 164, 251 

Fig 1: Identifying Rail Components
G06878026Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install     
DANGER 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 
DANGER Risk of explosion  caused by ignition of flammable products, risk of poisoning  caused by inhaling fuel vapors or swallowing fuel as well as risk of injury  to skin and eyes exposed to 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
DANGER Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, lift gates or sliding roof Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A
1.1 Removes strut tower brace Model 164.8 only
IMPORTANT Remove strut tower brace from strut tower mounts.		 AR62.30-P-2500GY
1.2 Remove partition wall between wheel wells Model 251 only AR62.30-P-2400RT
2 Remove engine cover IMPORTANTInstallation:  Do not fit engine cover until fuel system has been leaked for leaks. AR01.10-P-2405GZB
3 Remove injection lines   AR07.16-P-1080GZB 
4 Disconnect electrical connectors from rail pressure sensor (B4/6)    
5 Disconnect electrical connectors from pressure regulator valve (Y74)    
6 Disconnect return line (2)    
7 Unscrew union nuts (3) on pressure lines (19/1) IMPORTANT When loosening union nuts (3), counterhold connection fittings for pressure lines (19/1).
IMPORTANTInstallation:  When tightening union nuts (3), counterhold connection fittings for pressure lines (19/1).		  
TORQUE SPECIFICATION *BA07.16-P-1025-01C 
TORQUE SPECIFICATION *BA07.16-P-1026-01C 
SPECIAL TOOL Box wrench bit Fig 2
8 Remove pressure lines (19/1) IMPORTANT Close connections of pressure lines (19/1) immediately after removal as a protection against contamination. Do not crush or deform pressure lines (19/1).  
SPECIAL TOOL Set of stop plugs Figure
9 Unscrew union nuts (3) on connecting line (19/2) IMPORTANT Close connections of connecting line (19/2) immediately after removal as a protection against contamination. Do not crush or deform connecting line (19/2).  
TORQUE SPECIFICATION *BA07.16-P-1024-01C 
SPECIAL TOOL Set of stop plugs Figure
SPECIAL TOOL Box wrench bit Fig 2
INSPECT Checking     
10 Check sealing cone for pressure lines (19/1) IMPORTANTInstallation:  In the case of visible pressure mark on a pressure line (19/1), replace it.  
11 Inspect taper gasket of connecting line (19/2) IMPORTANTInstallation:  A connecting line (19/2) has visible pressure marks must be replaced.  
12 Remove bolt (1) TORQUE SPECIFICATION *BA07.16-P-1003-01C 
13 Remove rails (21) IMPORTANTInstallation:  Finger-tighten union nuts (3) of connecting line (19/2) and pressure line (19/1) and then tighten bolts (1).  
14 Install in the reverse order    
DANGER 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 moving off.
Wear closed and close-fitting work clothes.
Do not touch hot or rotating parts.		 AS00.00-Z-0005-01A
15 Check fuel system for leaks with engine running    
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation Engine 642
BA07.16-P-1003-01C Bolt, rail to cylinder head Nm 14
BA07.16-P-1024-01C Connecting line between left and right rail M15 Nm 27
BA07.16-P-1025-01C Pressure line to high-pressure pump M14 Nm 33
BA07.16-P-1026-01C Pressure line to high-pressure pump to rail M15 Nm 27
Fig 2: Identifying Box Wrench Bit (000 589 68 03 00)
G06878027Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Set Of Stop Plugs (129 589 00 9100)
G06878028Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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