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

ENGINE 276.8 in MODEL 205 

MODIFICATION NOTES

24.9.14 Union nut, fuel line to diagnostic socket   BA07.03-P-1008-01D
24.9.14 Union nut, fuel line to high-pressure pump   BA07.03-P-1002-01D
24.9.14 Union nut, fuel line to fuel distributor   BA07.03-P-1001-01D
Fig 1: Identifying Rail Remove/Install Components
G10132539Courtesy 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-0003LW
NOTES Notes on battery AH54.10-P-0001-01A
2 Remove air filter housing on the left or right When removing the left or right rail (1)  
AR09.10-P-1150MMV
3 Remove crash plate and insulation on the high-pressure pump   AR07.02-P-1020MMV 
4 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
5 Relieve fuel pressure in fuel high-pressure circuit   AR07.03-P-1460-02MM
6 Remove soundproofing over rail (1)    
7 Loosen high-pressure line and low-pressure line on rail (1) and high-pressure pump NOTES
Thoroughly clean area around the fuel high pressure circuit so that no dirt can find its way into the fuel injection system.
Failure of the fuel injection system can occur otherwise.
NOTES
Do not kink or bend high-pressure line and low-pressure line.
This prevents leaks and damage.		  
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 
TORQUE SPECIFICATION Union nut, fuel line to service connection *BA07.03-P-1008-01D 
8 Detach low-pressure line at high-pressure pump   AR07.02-P-1020MMV 
NOTES
Do not kink or bend high-pressure line and low-pressure line.
This prevents leaks and damage.
TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01D 
9 Disconnect engine wiring harness at rail (1), fuel pressure and temperature sensor (B4/25), right exhaust camshaft Hall sensor (B6/7)   AR15.18-P-1000-03MMV
10 Remove screw/bolts (1s) from rail (1) 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.		  
TORQUE SPECIFICATION Screw/bolt, fuel distributor to cylinder head cover *BA07.52-P-1001-01G 
11 Remove hold-down tool (3) between rail (1) and fuel injectors (Y76)    
12 Mark fuel injectors (Y76) relative to the respective cylinder IMPORTANT When reusing the fuel injectors (Y76) they must be inserted into the cylinder in which the fuel injectors (Y76) were previously installed.  
13 Detach rail (1) from fuel injectors (Y76)    
14 Remove fuel injectors (Y76)   AR07.03-P-0004MMV 
IMPORTANT Fuel injectors (Y76) must be removed since the rail (1) may only jointly be installed with the fuel injectors (Y76).
IMPORTANT When reusing the fuel injectors (Y76) they must be inserted into the cylinder in which it was previously installed.
IMPORTANT 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.
In case of jammed fuel injectors (Y76):
↓
Remove injection nozzles
AR07.03-P-0004-03MM
SPECIAL TOOL Puller Figure
INSPECT Check     
15 Check high-pressure line for damage and replace if necessary   AR07.03-P-1010-03MM
NOTES
The sealing cone for high-pressure lines must be checked before assembly.
Do this to avoid leaks and damage.
Assembly cleaner *BR00.45-Z-1028-04A 
CLEAN Clean     
16 Clean fuel connections on fuel injectors (Y76) NOTES
During cleaning the fuel connections must be held downwards.
Dirt will get into the openings otherwise.		  
Assembly cleaner *BR00.45-Z-1028-04A 
INSTALLING Install     
17 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 2
18 Replace seal (2) on spilling of the rail (1)    
19 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
20 Insert fuel injectors (Y76) into rail (1) and fasten in place using the hold-down tools (3) IMPORTANT When reusing the fuel injectors (Y76) they must be inserted into the cylinder in which the fuel injectors (Y76) were previously installed.
INSTALLATION IMPORTANT Replace hold-down tool (3).		  
21 Insert rail (1) with fuel injectors (Y76) into the cylinder head    
22 Screw in screw/bolts (1s) for the rail (1) TORQUE SPECIFICATION Screw/bolt, fuel distributor to cylinder head cover
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.		 *BA07.52-P-1001-01G 
23 Attach high-pressure line and low-pressure line NOTES
Thoroughly clean area around the fuel high pressure circuit so that no dirt can find its way into the fuel injection system.
Failure of the fuel injection system can occur otherwise.
NOTES
Do not kink or bend high-pressure line and low-pressure line.
Otherwise leaks and damage may occur.		  
TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01D 
TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01D 
TORQUE SPECIFICATION Screw/bolt, fuel line service connection to cylinder head cover *BA07.03-P-1003-01D 
TORQUE SPECIFICATION Screw/bolt, fuel line clamps *BA07.03-P-1005-01D 
TORQUE SPECIFICATION Union nut, fuel line to service connection *BA07.03-P-1008-01D 
Assembly cleaner
The sealing cone for the high-pressure line and low-pressure line must be checked before assembly.
↓
The work instructions absolutely must be observed for assembly work		 *BR00.45-Z-1028-04A 
Mount high-pressure lines. AR07.03-P-1010-02MMA
24 Mount engine wiring harness from rail (1) and fuel injectors (Y76)   AR15.18-P-1000-03MMV
25.1 Connect electrical connection to fuel pressure and temperature sensor (B4/25) When installing left rail (1)  
25.2 Connect electrical connection on RH exhaust camshaft Hall sensor (B6/7) When installing right rail (1)  
26 Install crash plate and insulation on the high-pressure pump   AR07.02-P-1020MMV 
27 Remove soundproofing over rail    
28 Install air filter housing on the left or right When removing the left or right rail (1)  
AR09.10-P-1150MMV
29 Attach ground line to battery   AR54.10-P-0003LW
30 Read out fault memory using the diagnostic system and clear if necessary    
REFER TO SELF-DIAGNOSTIC SYSTEMS AD00.00-P-2000-04B
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
31 Check fuel system for leaks with engine running
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-1005-01D Screw/bolt, fuel line clamps 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
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1008-01D Union nut, fuel line to service connection Stage 1 Nm 15
Stage 2 ∠° 90
FUEL DISTRIBUTOR

Number Designation ENGINE 276
BA07.52-P-1001-01G Screw/bolt, fuel distributor to cylinder head cover Nm 9
Fig 2: Identifying Drift (278 589 01 15 00)
G09974824Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Pressure Hose (119 589 04 63 00)
G07449508Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Puller (278 589 00 33 00)
G09974823Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Assembly Tool (272 589 00 43 00)
G09974811Courtesy 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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