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

ENGINE 642 in MODEL 164, 251 

Fig 1: Identifying Rail Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	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 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
	Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, liftgates 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 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 trim panel	Do not fit engine cover until fuel system has been leaked for leaks.
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)	When loosening union nuts (3), counterhold connection fittings for pressure lines (19/1). When tightening union nuts (3), counterhold connection fittings for pressure lines (19/1).
			*BA07.16-P-1025-01C
			*BA07.16-P-1026-01C
		Box wrench bit	Fig 2
8	Remove pressure lines (19/1)	Close connections of pressure lines (19/1) immediately after removal as a protection against contamination. Do not crush or deform pressure lines (19/1).
		Set of stop plugs	Figure
9	Unscrew union nuts (3) on connecting line (19/2)	Close connections of connecting line (19/2) immediately after removal as a protection against contamination. Do not crush or deform connecting line (19/2).
			*BA07.16-P-1024-01C
		Set of stop plugs	Figure
		Box wrench bit	Fig 2
	Checking
10	Check sealing cone for pressure lines (19/1)	In the case of visible pressure mark on a pressure line (19/1), replace it.
11	Inspect taper gasket of connecting line (19/2)	A connecting line (19/2) has visible pressure marks must be replaced.
12	Remove bolt (1)		*BA07.16-P-1003-01C
13	Remove rails (21)	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
	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)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA