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

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ENGINE 642 in MODEL 207, 212, 218, 221 

Shown on engine 642 without code 927 (Exhaust treatment EURO 6 technology) 

Fig 1: Rail Remove/Install Components - Shown On Engine 642 Without Code 927
G09974607Courtesy of MERCEDES-BENZ USA

Shown on engine 642 with code 927 (Exhaust treatment EURO 6 technology) 

Fig 2: Rail Remove/Install Components - Shown On Engine 642 With Code 927 (1 Of 2)
G09974608Courtesy of MERCEDES-BENZ USA
Fig 3: Rail Remove/Install Components - Shown On Engine 642 With Code 927 (2 Of 2)
G09974609Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
1 Remove injection lines   AR07.16-P-1080SXI 
2 Expose engine wiring harness. ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)
IMPORTANT To do this unfasten on cable duct (4) retaining clip (arrows) and cable tie.
INSTALLATION IMPORTANT Replace cable tie.		  
3 Disconnect electrical connection on condensation sensor (B76/1) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
4 Detach ground line (5) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
5 Disconnect electrical connections at the glow plugs (R9) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
6 Disconnect electrical connections (6) at temperature sensor upstream of turbocharger (B19/11) and DPF differential pressure sensor (B28/8) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
7 Disconnect electrical connection at fuel pressure sensor (B4/7) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
8 Disconnect electrical connections (8, 9) at the combustion chamber pressure sensors (B4/34, B4/35, B4/36, B4/37, B4/38, B4/39) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
9 Disconnect electrical connection (11) at right hot film MAF sensor (B2/7) or left hot film MAF sensor (B2/6) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
10 Disconnect electrical connection at vent line heater element (R39/1). ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
11 Disconnect electrical connection (12) at intake port shutoff actuator motor (M55) and expose electrical wiring harness. ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
12 Disconnect electrical connection (13) at boost pressure positioner (Y77/1) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
13 Disconnect electrical connections to fuel injectors (Y76) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
14 Disconnect the electrical connection at the camshaft Hall sensor (B6/1) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
15 Disconnect electrical connection (14) at exhaust gas recirculation actuator (Y27/9). ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
16 Disconnect electrical connection (15) at exhaust pressure sensor (B60). ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
17 Disconnect electrical connection on rail pressure sensor (B4/6) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)  
18 Lead out engine wiring harness under the injection lines and place to one side to the front together with cable duct (4) ENGINE 642 in MODEL 207, 212, 218 with CODE 927 (Emission control system with Euro 6 technology)
IMPORTANT Fix engine wiring harness with cable duct (4) to the front.		  
19 Disconnect electrical connection on pressure regulating valve (Y74)    
20 Disconnect return line (2)    
21 Unscrew union nuts (3) for pressure lines (19/1) IMPORTANT When loosening union nuts (3), counterhold connection fittings for pressure lines (19/1).
INSTALLATION IMPORTANT For tightening the union nuts (3) counterhold the connection fitting for pressure lines (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 
22 Remove pressure lines (19/1) IMPORTANT Close off connections for pressure lines (19/1) immediately after removal as a protection against contamination. Do not crush or deform pressure lines (19/1).  
    SPECIAL TOOL Record plug Fig 4
23 Unscrew union nuts (3) on fuel lines (19/2) IMPORTANT Close off connections for fuel lines (19/2) immediately after removal as a protection against contamination. Do not crush or deform fuel lines (19/2).  
    TORQUE SPECIFICATION Connecting line between left and right rail *BA07.16-P-1024-01C 
    SPECIAL TOOL Record plug Fig 4
INSPECT Check     
24 Check sealing cone for pressure lines (19/1) INSTALLATION IMPORTANT If there are pressure lines replace pressure marks (19/1).  
25 Check sealing cone for fuel lines (19/2) INSTALLATION IMPORTANT If there are pressure marks replace fuel lines (19/2).  
26 Remove screw/bolt (1) TORQUE SPECIFICATION Screw/bolt, rail to cylinder head *BA07.16-P-1003-01C 
27 Remove rails (21) INSTALLATION IMPORTANT Lay on union nuts (3) for fuel lines (19/2) and the pressure lines (19/1) finger-tight, then tighten down screw/bolts (1).  
28 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
29 Check fuel system for leaks with engine running    
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 642
BA07.16-P-1003-01C Screw/bolt, rail to cylinder head Nm 14
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 642
BA07.16-P-1024-01C Connecting line between left and right rail M15 Nm 27
COMMON RAIL DIESEL INJECTION (CDI)

Number Designation ENGINE 642
BA07.16-P-1025-01C Pressure line to high-pressure pump M14 Nm 33
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
Fig 4: Identifying Record Plug (129 589 00 91 00)
G09974610Courtesy of MERCEDES-BENZ USA
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