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

ENGINE 642 in MODEL 166

Fig 1: Identifying Rail Remove/Install Components (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Rail Remove/Install Components (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Risk of explosion caused by 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 system when it is pressurized.	AS07.16-Z-0001-01A
1	Remove injection line for the respective rail (21)		AR07.16-P-1080OGR
2	Unscrew union nuts (3) on connecting line (19/2)	Connecting line between left and right rail	*BA07.16-P-1024-01C
3	Detach connecting line (19/2) to charge air distribution line	Fuel line to cylinder head cover/lifting eye/charge air manifold	*BA07.16-P-1022-01C
4	Disconnect the electrical connector on the sensor (B4/6)	When removing right rail (21)
5	Disconnect electrical connector at pressure regulator valve (Y74)	When removing left rail (21)
6	Open clamp and return hose (2) on (21)	When removing left rail (21) Replace clamp if necessary.
7	Unscrew union nut (3) for the pressure line (19/1) and detach pressure line (19/1) from the left cylinder head cover and the high-pressure pump	Use a box wrench bit for the union nut on the high-pressure pump. Close off connections for pressure line (19/1) immediately after removal as a protection against contamination. Do not crush or deform pressure line (19/1).
		Fuel line to cylinder head cover/lifting eye/charge air manifold	*BA07.16-P-1022-01C
		Pressure line to high-pressure pump	*BA07.16-P-1025-01C
		Pressure line to high-pressure pump to rail	*BA07.16-P-1026-01C
		Box wrench bit	Fig 4
		Record plug	Figure
	Check
8	Check sealing cone for pressure line (19/1)	In the case of visible pressure mark on the pressure line (19/1), replace it.
9	Check sealing cone for connecting line (19/2)	This must be replaced in the case of visible pressure marks on the connecting line (19/2).
10	Remove bolt (1)	Screw/bolt, rail to cylinder head	*BA07.16-P-1003-01C
11	Remove rails (21)	Finger-tighten union nuts (3) of connecting line (19/2) and pressure line (19/1) and then tighten screw/bolts (1).
12	Install in the reverse order
	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off 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