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Home >> Mercedes Benz >> 2014 >> SL63 AMG >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Mixture Formation - 231 Chassis >> Testing & Repair >> Remove/install fuel rail >> Remove/install fuel rail - AR07.03-P-1010RKA

Remove/install fuel rail - AR07.03-P-1010RKA

ENGINE 276 in MODEL 231 

Shown on model 231.457 

Fig 1: Fuel Rail Remove/Install Components - Shown On Model 231.457 (1 Of 2)
G11128357Courtesy of MERCEDES-BENZ USA
Fig 2: Fuel Rail Remove/Install Components - Shown On Model 231.457 (2 Of 2)
G11128358Courtesy of MERCEDES-BENZ USA
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 General information on work on gasoline direct injection system   AH07.00-P-2000-01A
REMOVING Remove     
1 Detach ground line from battery   AR54.10-P-0003RK
2.1 Remove air filter housing Engine 276.9 in model 231
When removing the right rail (1).		  
2.2 Remove both air filter housings Engine 276.8 in model 231
When removing the left or right rail (1).		 AR09.10-P-1150RKA
3 Remove right or left soundproofing over the rail (1)    
4 Remove connecting flange of the intake manifold Engine 276.9 in model 231 AR09.20-P-1961RKA
5 Remove crash plate and insulation on the high-pressure pump   AR07.02-P-1020RKA 
6 Relieve fuel pressure over diagnostic socket   AR07.03-P-1460-01VA
TORQUE SPECIFICATION Cap on service connection *BA07.03-P-1007-01D 
SPECIAL TOOL Pressure hose Figure
7 Relieve fuel pressure in fuel system high-pressure circuit   AR07.03-P-1460-02MM
8 Detach high-pressure line holder between right rail (1) and high-pressure pump on right cylinder head cover Engine 276.8 in model 231  
9 Detach high-pressure line between right rail (1) and high-pressure pump at high-pressure pump and right rail (1)    
10.1 Detach clamps for high-pressure line Engine 276.9 in model 231  
10.2 Detach bracket of the high-pressure line at the high-pressure pump housing and the left cylinder head cover Engine 276.8 in model 231  
11 Detach low-pressure line at high-pressure pump    
12.1 Detach high-pressure line at left and right rail (1) Engine 276.8 in model 231  
12.2 Detach high-pressure line at left rail (1) Engine 276.9 in model 231  
13 Detach diagnostic socket at left cylinder head cover    
14 Disconnect electrical connection on right exhaust camshaft Hall sensor (B6/7) Engine 276.9 in model 231
When removing the right rail (1).		  
15 Disconnect electrical connection on fuel pressure and temperature sensor (B4/25) When removing the left rail (1).  
16 Detach engine wiring harness on the rail (1)   AR01.00-P-2410-02RKA
17 Remove support (4) for the intake manifold Engine 276.9 in model 231  
18 Remove screw/bolts (1s) NOTES Unscrew screw/bolts (1s) alternately each by half a revolution. Begin in the center of the rail (1) and work outwards.
Damage to the rail (1) can occur otherwise.		  
19 Remove hold-down device (3) between rail (1) and fuel injectors (Y76)    
20 Mark fuel injectors (Y76) relative to the respective cylinder IMPORTANT When reusing the fuel injectors they (Y76) must be inserted into the cylinder in which it was previously installed. AR07.03-P-0004RKA 
21 Detach rail (1) from fuel injectors (Y76)    
22 Remove fuel injectors (Y76) IMPORTANT Engine oil which comes out during disassembly of the rail (1) or from the fuel injectors (Y76) is safe. The rail (1) or the fuel injectors (Y76) can be re-used.
IMPORTANT All fuel injectors (Y76) must be pulled out since the rail (1) may only jointly be installed with the fuel injectors (Y76).
In case of jammed fuel injectors (Y76) ↓
Remove injection nozzle.		 AR07.03-P-0004-03MM
SPECIAL TOOL Puller Figure
CLEAN Clean     
23 Clean fuel connections on fuel injectors (Y76) NOTES During cleaning the fuel connections must be held downwards.
Dirt can enter the openings otherwise.		  
INSPECT Check     
24 Check high-pressure line for damage and replace if necessary NOTES The sealing cone for high-pressure lines must be checked before assembly.
Do this to avoid leaks and damage.		 AR07.03-P-1010-03MM
Assembly cleaner *BR00.45-Z-1028-04A 
INSTALLING Install     
25 Replace sealing packages for the fuel injectors (Y76) on rail (1)   AR07.03-P-0004-02MM
Assembly cleaner *BR00.45-Z-1028-04A 
SPECIAL TOOL Drift Fig 3
26 Replace sealing rings and seal at fuel injectors (Y76)   AR07.03-P-0004-01MM
Assembly cleaner *BR00.45-Z-1028-04A 
SPECIAL TOOL Assembly tool Figure
27 Replace seal (2) on overflow connector of the rail (1)    
28 Insert fuel injectors (Y76) into the rail (1) and fasten in place using the hold-down tools (3) IMPORTANT When reusing the fuel injectors they (Y76) must be inserted into the cylinder in which it was previously installed.
IMPORTANT Fuel injectors (Y76) may only be installed again in combination with the rail (1) (as a whole).
IMPORTANT Replace Hold-down tool (3).		  
29 Insert rail (1) with fuel injectors (Y76) into the cylinder head    
30 Screw in screw/bolts (1s) NOTES Screw in screw/bolts (1s) alternately each by half a revolution. Begin in the center of the rail (1) and work outwards.
Damage to the rail (1) can occur otherwise.
TORQUE SPECIFICATION Screw/bolt, fuel distributor to cylinder head cover		 *BA07.52-P-1001-01G 
31 Install support (4) for the intake manifold Engine 276.9 in model 231  
32 Mount engine wiring harness from rail (1) and fuel injectors (Y76)   AR01.00-P-2410-02RKA
33 Connect electrical connection to fuel pressure and temperature sensor (B4/25) When installing the left rail (1).  
34 Connect electrical connection on RH exhaust camshaft Hall sensor (B6/7) Engine 276.9 in model 231
When installing the right rail (1).		  
35 Mount diagnostic socket on left cylinder head cover TORQUE SPECIFICATION Screw/bolt, fuel line service connection to cylinder head cover *BA07.03-P-1003-01D 
36.1 Mount high-pressure line on left and right rail (1) Engine 276.8 in model 231 AR07.03-P-1010-02MMA
TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01D 
36.2 Mount high-pressure line on left rail (1) Engine 276.9 in model 231 AR07.03-P-1010-02MMA
TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01D 
37 Mount low-pressure line at high-pressure pump   AR07.03-P-1010-02MMA
TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01D 
38.1 Detach bracket of the high-pressure line at the high-pressure pump housing and the left cylinder head cover Engine 276.8 in model 231
TORQUE SPECIFICATION Screw/bolt, additional bracket for high-pressure line to high pressure pump drive housing		 *BA07.03-P-1006-01D 
38.2 Mount clamps for high-pressure line Engine 276.9 in model 231 AR07.03-P-1010-02MMA
TORQUE SPECIFICATION Screw/bolt, fuel line clamps *BA07.03-P-1005-01D 
39 Mount high-pressure line between right rail (1) and high-pressure pump at high-pressure pump and right rail (1)   AR07.03-P-1010-02MMA
TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01D 
TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01D 
40 Detach high-pressure line holder between right rail (1) and high-pressure pump on right cylinder head cover Engine 276.8 in model 231
TORQUE SPECIFICATION Screw/bolt, fuel line holder to cylinder head cover		 *BA07.03-P-1004-01D 
41 Attach crash plate and insulation on the high-pressure pump   AR07.02-P-1020RKA 
42 Install connecting flange for intake manifold Engine 276.9 in model 231 AR09.20-P-1961RKA
43 Remove right or left soundproofing over the rail (1)    
44.1 Install air filter housing Engine 276.9 in model 231
When installing the right rail (1).
TORQUE SPECIFICATION Bolt, air filter to cylinder head cover		 *BA09.10-P-1001-01M 
TORQUE SPECIFICATION Bolt, air filter to air intake pipe support brace *BA09.10-P-1002-01M 
44.2 Install both air filter housing Engine 276.8 in model 231
When installing the left or right rail (1).		 AR09.10-P-1150RKA
45 Mount ground line on battery   AR54.10-P-0003RK
46 Read out fault memory using the diagnostic system and clear if necessary    
REFER TO SELF-DIAGNOSTIC SYSTEMS   AD00.00-P-2000-04A
INSPECT Check     
47 Check fuel high-pressure circuit for leaktightness   AR07.03-P-1010-04MM
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
48 Carry out an engine test run, checking the engine for proper operation and leaktightness    
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1001-01D Union nut, fuel line to fuel distributor Stage 1 Nm 15
Stage 2 ∠° 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1002-01D Union nut, fuel line to high-pressure pump Stage 1 Nm 15
Stage 2 ∠° 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1003-01D Screw/bolt, fuel line service connection to cylinder head cover Nm 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1004-01D Screw/bolt, fuel line holder to cylinder head cover Nm 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1005-01D Screw/bolt, fuel line clamps Nm 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1006-01D Screw/bolt, additional bracket for high-pressure line to high pressure pump drive housing Nm 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 276
BA07.03-P-1007-01D Cap on service connection Plastic Nm 2
Metal Nm 15
FUEL DISTRIBUTOR

Number Designation Engine 276
BA07.52-P-1001-01G Screw/bolt, fuel distributor to cylinder head cover Nm 9
AIR FILTER

Number Designation Engine 276.9
BA09.10-P-1001-01M Bolt, air filter to cylinder head cover Nm 9
AIR FILTER

Number Designation Engine 276.9
BA09.10-P-1002-01M Bolt, air filter to air intake pipe support brace Nm 9
Fig 3: Identifying Drift (278 589 01 15 00)
G10247781Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Pressure Hose (119 589 04 63 00)
G07742723Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Puller (278 589 00 33 00)
G11128361Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Assembly Tool (272 589 00 43 00)
G10247789Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
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