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

ENGINE 157 in MODEL 463

MODIFICATION NOTES

25.03.2013	Special tool Drift 278 589 00 15 00 changed into 278 589 01 15 00	Operation step 17
04.07.2016	Union nut, Fuel line to fuel rail		BA07.03-P-1001-01E
04.07.2016	Union nut, Fuel line to high-pressure pump		BA07.03-P-1002-01E

Fig 1: Fuel Rail Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	Remove
	Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.	No parts of the body or limbs should be within the operating area when the components are moving.	AS00.00-Z-0011-01A
	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
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
1	Detach ground line from battery		AR54.10-P-0003GW
	Notes on battery		AH54.10-P-0001-01A
2	Remove air filter housing		AR09.10-P-1150GW
3	Remove insulation on rail (1)
4	Remove insulation from high-pressure pumps
5	Remove ME-SFI [ME] control unit		AR07.08-P-7008GW
6	Disconnect electrical connection at fuel pressure and temperature sensor	When removing right rail (1)
7	Detach engine wiring harness from rail (1) and fuel injectors (Y76)		AR01.00-P-2410-02GW
8	Relieve fuel pressure through service valve		AR07.03-P-1460-01GW
		Protective cap on service valve	*BA07.03-P-1007-01E
		Pressure hose	Figure
9	Relieve fuel pressure in high-pressure system		AR07.03-P-1460-02MM
10	Remove high-pressure lines for high-pressure pumps on rails (1)	Do not kink or bend high-pressure lines. This is to avoid leaks and damage if the high- pressure lines are possibly used again (after successfully passing checking).
11	Remove high-pressure line between rails (1)	Do not kink or bend high-pressure lines. This is to avoid leaks and damage if the high- pressure lines are possibly used again (after successfully passing checking).
12	Remove screw/bolts (1s) from rail (1)	Screw in and screw out screw/bolts (1s) alternately by half a turn from the center to the outside for removal or installation of the rail (1). Damage to the rail (1) can occur otherwise.
13	Remove hold-down device (3) between rail (1) and fuel injectors (Y76)
14	Detach rail (1) from fuel injectors (Y76)
15	Remove fuel injectors (Y76)		AR07.03-P-0004GW
		When reusing the fuel injectors they (Y76) must be inserted into the cylinder in which it was previously installed. Fuel injectors (Y76) must be pulled out since the rail (1) may only jointly be installed with the fuel injectors (Y76).
		Puller In case of jammed fuel injectors (Y76): ↓	Figure
		Remove jammed fuel injectors	AR07.16-P-1000-03GW
	Clean
16	Clean fuel connections on fuel injectors (Y76)	During cleaning the fuel connections must be held downwards. This prevents dirt getting into the openings.
	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
		Drift	Fig 2
18	Insert fuel injectors (Y76) into rail (1) and fasten in place using the hold-down tools (3)	Replace hold-down tool (3).
19	Insert seal (2) for overflow connector for rail (1) in the cylinder head cover	Check seal (2) before assembly and replace if necessary.
20	Insert rail (1) with fuel injectors (Y76) into the cylinder head
21	Screw in screw/bolts (1s) for the rail (1)	Screw/bolt, fuel distributor to cylinder head cover	*BA07.52-P-1001-01G
22	Install high-pressure lines	Do not kink or bend high-pressure lines. This prevents leaks and damage. The sealing cone for the high-pressure line must be checked before assembly. The work instructions absolutely must be observed for assembly work: ↓
		Check high-pressure lines	AR07.03-P-1010-03MM
		Mount high-pressure lines.	AR07.03-P-1010-02MMB
		Check fuel high pressure circuit.	AR07.03-P-1010-04MM
		Union nut, fuel line to fuel distributor	*BA07.03-P-1001-01E
		Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01E
		Bolt, fuel line service valve to cylinder head cover	*BA07.03-P-1003-01E
		Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head	*BA07.03-P-1004-01E
		Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase	*BA07.03-P-1005-01E
		Bolt, fuel line clamp to charge air distribution line	*BA07.03-P-1006-01E
		Fuel line union nut on service valve	*BA07.03-P-1008-01E
		Assembly cleaner	*BR00.45-Z-1028-04A
23	Mount engine wiring harness from rail (1) and fuel injectors (Y76)		AR01.00-P-2410-02GW
24	Connect electrical connection at fuel pressure and temperature sensor	When installing right rail (1)
25	Install ME-SFI [ME] control unit		AR07.08-P-7008GW
26	Install insulation on high-pressure pumps
27	Install insulation on rail (1)
28	Install air filter housing
29	Mount ground line on battery		AR54.10-P-0003GW
30	Read out and clear the fault memory using Star Diagnosis
			AD00.00-P-2000-04A
	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