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

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ENGINES 651 in MODELS 166, 172, 204, 207, 212, 218, 221

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

Courtesy of MERCEDES-BENZ USA

Fig 2: 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 systems when they are under pressure	AS07.16-Z-0001-01A
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes about Common-Rail components		AH07.16-P-0002-01TX
1	Remove cylinder head cover trim
2	Remove section for the partition wall on the left and center	Model 166
3	Remove injection lines	Always replace injection lines and install free of tension. Always install high-pressure line free of tension.	AR07.16-P-1080CD
4	Disconnect electrical connectors (7)
5	Disconnect electrical connector (8)	Except model 166
6	Loosen fastening clip (9) and lift cable shaft (10) upwards	Cable holder which are separated when removing, must be fitted again at the same position when installing.
7	Unscrew banjo bolt for return line (3)	All connections must be closed off after disassembly of the injection lines. The high-pressure pump components may be damaged otherwise. Stop plugs are available as a replacement part for the injection system. Repeated usage is not allowed. Ensure scrupulous cleanliness!
		Replace sealing rings.	*BA07.16-P-1004-01H
8	Detach upper holder from high-pressure line and unscrew high-pressure line from rail (5).		AR07.16-P-1080CD
9	Remove screws/bolts (4)		*BA07.16-P-1003-01H
10	Take out rail (5)
11	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
12	Check fuel system for leaks with engine running	Carry out visual inspection.

COMMON RAIL DIESEL INJECTION (CDI)

Number	Designation		ENGINE 651
BA07.16-P-1003-01H	Screw/bolt, rail to cylinder head	Nm	14
BA07.16-P-1004-01H	Banjo bolt, return line to rail	Nm	25