Remove/Install Right High Pressure Line - AR07.03-P-1002MNJ
Engine 178.9 In Model 190.381
| 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 | |
| Risk of injury . Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. |
AS00.00-Z-0017-01A | |
| Topical note | Notes on working in engine compartment | AH60.00-P-0042-01RG | |
| Topical note | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| Topical note | Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | |
| Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | |
| General information on work on gasoline direct injection system | AH07.00-P-2000-01A | ||
| Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | AH00.00-P-0015-01CW | ||
| Remove | |||
| 1 | Clamp off ground line of on-board electrical system battery (G1). | AR54.10-P-0003RG | |
| 2 | Remove cover (20). | ||
| 3 | Remove seal (21). | ||
| 4 | Remove nut (23). | ||
| 5 | Remove screws/bolts (22). | ||
| 6 | Remove feed-through grommet (24) with vacuum hose from partition (25) and place to one side. | ||
| 7 | Remove wiring harness (26) from partition (25) and remove partition (25). | Fig 2 | |
| 8 | Remove fuel pressure via the service connection. | AR07.03-P-1460-01MNA | |
| Fig 4 | |||
| 9 | Remove ME-SFI [ME] control unit (N3/10). | AR07.08-P-7013MNJ | |
| 10 | Remove engine wiring harness (4) from strut (9). | ||
| 11 | Remove screws (2, 5) and remove strut (9). | ||
| 12 | Unclip engine wiring harness (4) from high-pressure line (14). | ||
| 13 | Unclip bleed line (6), remove from right cylinder head cover, and seal with suitable means. | ||
| 14 | Remove bleed line (10) from right oil separator and seal opening with suitable stop plugs. | Fig 1 | |
| 15 | Remove screws (3). | ||
| 16 | Release and disconnect electrical connectors (7, 8) and place engine wiring harness (4) to one side. | ||
| 17 | Remove noise insulation (1). | ||
| 18 | Release fuel pressure in the fuel high-pressure circuit. | AR07.03-P-1460-02MM | |
| Fig 3 | |||
| 19 | Remove holders (15) with high-pressure line (14) from cylinder head cover. | ||
| 20 | Clean area around high-pressure line (14). | Thoroughly clean area around high-pressure line (14) at points to be disconnected. Failure can occur otherwise to the fuel system. Assembly cleaner |
*BR00.45-Z-1028-04A |
| 21 | Remove high-pressure line (14) and seal openings with suitable stop plugs. | Do not kink or bend high-pressure line (14). Otherwise leaks and damage can occur. |
Fig 1 |
| Fig 3 | |||
| Check | |||
| 22 | Check high-pressure line (14) for damage. | If high-pressure line (14) is reused. Vernier caliper |
AR07.03-P-1010-03MM |
| Assembly cleaner If damage is present, ↓ Replace high-pressure line (14). |
*BR00.45-Z-1028-04A | ||
| Install | |||
| 23 | Modify holders (15) of high-pressure line (14). | When replacing high-pressure line (14). | |
| 24 | Remove stop plugs, install high-pressure line (14), and tighten slightly by hand. | While positioning, avoid contact and chafing between sealing heads of lines and the fittings. Otherwise leaks and damage can occur. |
*BA07.02-P-1001-01E |
| Fig 1 | |||
| 25 | Attach holders (15) with high-pressure line (14) to cylinder head cover. | *BA07.03-P-1004-01H | |
| 26 | Tighten high-pressure line (14) on high-pressure fuel pump (12) and rail (11). | *BA07.03-P-1001-01H | |
| Fig 3 | |||
| 27 | Install noise insulation (1). | ||
| 28 | Connect and lock electrical connectors (7, 8). | ||
| 29 | Position engine wiring harness (4) and tighten screws (3). | *BA15.18-P-1001-01G | |
| 30 | Remove stop plug and attach bleed line (10) to right oil separator. | Fig 1 | |
| 31 | Expose previously sealed bleed line (6), clip in, and attach to right cylinder head cover. | *BA01.20-P-1001-01J | |
| 32 | Clip engine wiring harness (4) into high-pressure line (14). | ||
| 33 | Install strut (9) and tighten screws (2, 5). | *BA62.30-P-1001-01I | |
| 34 | Attach engine wiring harness (4) to strut (9). | ||
| 35 | Install ME-SFI control unit (N3/10). | AR07.08-P-7013MNJ | |
| 36 | Install dust cap of service connection. | *BA07.03-P-1005-01H | |
| 37 | Install partition (25) and attach electrical wiring harness (26) to partition (25). | ||
| 38 | Attach feed-through grommet (24) with vacuum hose to partition (25). | ||
| 39 | Screw in screws/bolts (22). | *BA68.74-P-1001-01D | |
| 40 | Attach nut (23). | *BA68.74-P-1002-01D | |
| 41 | Install seal (21). | ||
| 42 | Install cover (20). | ||
| 43 | Clip on ground line of the on-board electrical system battery (G1). | AR54.10-P-0003RG | |
| Check | |||
| 44 | Check fuel high-pressure circuit for leak tightness. | ||
| AD00.00-P-2000-04B | |||
| AR07.03-P-1010-04MM | |||
| Risk of burn injuries , suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. | Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area. | AS49.00-Z-0001-01A | |
| 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 | |
| 45 | Perform engine test run. While doing so, check engine for proper operation and leak tightness. |
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER
| Number | Designation | Engine 178 | |
|---|---|---|---|
| BA01.20-P-1001-01J | Bolt, vent line to cylinder head cover/turbocharger | Nm | 9 |
INJECTION PUMP, HIGH-PRESSURE FUEL PUMP
| Number | Designation | Engine 178 | |
|---|---|---|---|
| BA07.02-P-1001-01E | Bolt, fuel system high pressure pump to cylinder head | Nm | 14 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 178 | |||
|---|---|---|---|---|---|
| BA07.03-P-1001-01H | Union nut, fuel line to fuel distributor/fuel system high-pressure pump | In case of reusability | Nm | 22 | |
| For new lines | Stage 1 | Nm | 15 | ||
| Stage 2 | ∠° | 90 | |||
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 178 | |
|---|---|---|---|
| BA07.03-P-1004-01H | Bolt, fuel line clamp to engine/bracket | Nm | 9 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 178 | |
|---|---|---|---|
| BA07.03-P-1005-01H | Dust protection cap to service connection | Nm | 1 |
ENGINE WIRING HARNESS
| Number | Designation | Engine 178 | |
|---|---|---|---|
| BA15.18-P-1001-01G | Bolt, engine wiring harness to cylinder head cover | Nm | 9 |
CROSS MEMBER AND FRONT REINFORCEMENT
| Number | Designation | Model 190 | ||
|---|---|---|---|---|
| BA62.30-P-1001-01I | Bolt, strut to body/retaining plate | M8 | Nm | 30 |
PARTITION WALL
| Number | Designation | Model 190 | |
|---|---|---|---|
| BA68.74-P-1001-01D | Bolt, partition wall to body | Nm | 7 |
PARTITION WALL
| Number | Designation | Model 190 | |
|---|---|---|---|
| BA68.74-P-1002-01D | Nut, partition wall to body | Nm | 8 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |