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

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ENGINE 642 in MODEL 207, 212, 218, 221, 222 

Shown on engine 642.9 

Fig 1: Injection Lines Of Common Rail Diesel Injection - Shown On Engine 642.9 (1 Of 2)
G09974682Courtesy of MERCEDES-BENZ USA

Shown on the left cylinder head 

Fig 2: Injection Lines Of Common Rail Diesel Injection - Shown On Engine 642.9 (2 Of 2)
G09974683Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER 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
DANGER Risk of explosion  caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A
IMPORTANT Notes about Common-Rail components   AH07.16-P-0002-01TX
1 Remove right or left air filter housing   AR09.10-P-1150SXI
2 Remove engine air intake duct downstream of air filter ENGINE 642 in MODEL 207, 212, 218, 222 AR09.10-P-8130OGE
ENGINE 642 in MODEL 221 AR09.10-P-8130SXI
3 Remove oil separator ENGINE 642 in MODEL 221
When taking off the right sound dampening (20)		  
4 Remove soundproofing (20) from right or left cylinder head cover    
5.1 Pull retainer for leak oil line connection (2) upwards and detach leak oil line (3) at the fuel injectors ENGINE 642 in MODEL 207, 212, 218, 221 AR07.03-P-9105A 
5.2 Turn retainer for leak oil line connection (2) counterclockwise and detach leak oil line (3) at the fuel injectors ENGINE 642 in MODEL 222 AR07.03-P-9105LFD
6 Unscrew bracket (4) of engine wiring harness ENGINE 642 in MODEL 207, 212, 218, 221  
7 Unscrew union nuts (5) from injection lines (21/6) INSTALLATION NOTES
Observe the differing torque specifications. Damage will occur to the fuel injectors or rail (21) otherwise.
IMPORTANT When working on injection system ensure scrupulous cleanliness! Clean connecting points before opening to protection against contamination.		  
TORQUE SPECIFICATION Union nut, pressure line to rail *BA07.16-P-1028-01C 
TORQUE SPECIFICATION Union nut, pressure line to injector *BA07.16-P-1029-01C 
8 Remove injection lines (21/6) IMPORTANT Close off all connections of injection lines (21/6) immediately after removal as a protection against contamination. Do not crush or deform injection lines (21/6).
INSTALLATION IMPORTANT Loosen rail (21) to assemble the injection lines (21/6) free of tension. Only retighten the screw/bolts after all injection lines (21/6) have been attached.		  
SPECIAL TOOL Box wrench bit Fig 4
SPECIAL TOOL Record plug Figure
9 Remove screw/bolt (6) and bracket    
10 Loosen rail (21) ENGINE 642 in MODEL 222 AR07.03-P-1010LFD
ENGINE 642 in MODEL 207, 212, 218, 221 AR07.03-P-1010SXI 
INSTALLATION IMPORTANT If all injection lines (21/6) are detached then the rail (21) must also be loosened and the injection lines (21/6) must be pushed in by hand all the way.
INSTALLATION IMPORTANT Only tighten rail (21) after installing the injection lines (21/6).		  
11 Remove pressure line (19/1) IMPORTANT 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).
TORQUE SPECIFICATION Pressure line to high-pressure pump		 *BA07.16-P-1025-01C 
TORQUE SPECIFICATION Pressure line to high-pressure pump to rail *BA07.16-P-1026-01C 
SPECIAL TOOL Record plug Figure
INSPECT Check     
12 Check sealing cone of injection lines (21/6) and the pressure line (19/1) INSTALLATION IMPORTANT For pressure marks replace the injection line (21/6) or pressure line (19/1).  
13 Install in the reverse order    
DANGER 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
14 Check fuel system for leaks with engine running    
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 642
BA07.16-P-1026-01C Pressure line to high-pressure pump to rail M15 Nm 27
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 642
BA07.16-P-1028-01C Union nut, pressure line to rail M15 Nm 27
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 642
BA07.16-P-1029-01C Union nut, pressure line to injector M14 Nm 33
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 642
BA07.16-P-1025-01C Pressure line to high-pressure pump M14 Nm 33
Fig 3: Identifying Record Plug (129 589 00 91 00)
G09974684Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Box Wrench Bit (000 589 68 03 00)
G09974685Courtesy of MERCEDES-BENZ USA
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