Remove/Install Fuel Rail - AR07.03-P-1010OGR

ENGINE 642 in model 166, 292

MODIFICATION NOTES

11.06.2019

Document completely revised.

Fig 1: Fuel Rail Components Location - Engine 642 In Model 166

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	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
	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
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Remove/install
1	Remove upper ENGINE cover.	: Do not install ENGINE cover until after the leak test.
2	Remove injection lines of the corresponding rail (21).	: Replace injection lines.	AR07.16-P-1080OGR
3	Unscrew union nuts (3) of the fuel line (19/2).	Fuel line between left and right tail	*BA07.16-P-1024-01C
4	Remove fuel line (19/2) from the charge-air distributor.	: Replace fuel line (19/2). Fuel line to cylinder head cover/lifting eye/charge air manifold	*BA07.16-P-1022-01C
5	Release and disconnect electrical connector from the high pressure fuel pressure sensor (B4/6).	When removing the right rail (21).
6	Release and disconnect electrical connector from the pressure regulating valve (Y74).	When removing left rail (21).
7	Open clamp and detach return hose (2) from the rail (21).	When removing left rail (21). : Check clamp for damage and replace if necessary.
8	Unscrew union nut (3) of the pressure line (19/1) and remove pressure line (19/1) from the left cylinder head cover and from the high-pressure pump.	: Install new pressure line (19/1). Use a box wrench bit for the union nut on the high-pressure pump. 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 2
9	Remove bolts (1).	Bolt, rail to cylinder head	*BA07.16-P-1003-01C
10	Remove rails (21).	: Tighten union nuts (3) of the fuel line (19/2) and pressure line (19/1) slightly by hand.
11	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
12	Check fuel system for leaks with ENGINE running.
13	Install ENGINE cover.