Remove/Install Left Fuel Rail With Fuel Injectors - AR07.03-P-1050MNL
Engine 176 in model 217, 222
MODIFICATION NOTES
| 22.05.2018 | Work procedure and method changed. | Entire document. |
Shown on model 222.983
| 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 | |
| Risk of injury
to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil |
Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers. |
AS18.00-Z-0001-01A | |
| Topical note | Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | |
| General information on work on gasoline direct injection system | AH07.00-P-2000-01A | ||
| Remove | |||
| 1 | Remove left high-pressure line. | AR07.03-P-1001MNL | |
| 2 | Remove cover (1). | ||
| 3 | Remove supply line from low-pressure line (2) | AR07.03-P-1121MNL | |
| 4 | Remove crash plate (3). | ||
| 5 | Remove soundproofing (4) at rail (10). | ||
| 6 | Remove bleed line (5) from cylinder head cover. | ||
| 7 | Remove filler neck for engine oil from cylinder head cover. | AR01.40-P-0004MNL | |
| 8 | Remove low-pressure line (2) with service connection and place to one side with connected hose connection. | AR07.03-P-1121MNL | |
| 9 | Release and disconnect electrical connector o the cylinder 5 intake CAMTRONIC actuator (Y49/15) and the cylinder 8 intake CAMTRONIC actuator (Y49/17). | ||
| 10 | Release and disconnect electrical connector o left fuel pressure and temperature sensor (B42/2). | ||
| 11 | Release and disconnect electrical connectors (8) of the fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). |
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| 12 | Remove screws (9). | Remove screws (9) alternately, in each case, by half a turn. Start in center of rail (10) and work outwards. Rail (10) will otherwise be damaged. |
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| 13 | Remove brackets (11). | ||
| 14 | Remove rail (10) from fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) and seal connections with suitable stop plugs. | Fig 2 | |
| 15 | Mark fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) relative to the respective cylinder. | When reusing the fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | |
| 16 | Remove fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) from cylinder head and seal injector well bores with suitable stop plugs. | AR07.03-P-0004-03MM | |
| Fig 4 | |||
| Fig 1 | |||
| 17 | Check fuel injectors for cylinders 5 to 8 (Y76/5 Y76/6, Y76/7, Y76/8) for external damage. | If damage is present, ↓ Replace respectively affected fuel injector. |
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| 18 | Check connection of fuel line at rail (10) for damage. | If sealing cone at rail (10) is damaged ↓ Replace rail (10). |
|
| 19 | Check left high-pressure line for damage. | If damage to sealing cone exists ↓ Replace left high-pressure line |
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| AR07.03-P-1001MNL | |||
| Install | |||
| 20 | Clean fuel connections on the fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | For cleaning the fuel connections, hold downwards. Otherwise, the fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) will fail. Immediately install fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) after removing the transport protective cap. Leaks can occur otherwise. |
|
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 21 | Install new sealing packages of fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) in the rail (10). | AR07.03-P-0004-02MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 5 | |||
| 22 | Install new sealing rings on the fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | AR07.03-P-0004-01MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 3 | |||
| 23 | Assign fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) to corresponding cylinders and clean injector shaft holes. | When reusing the fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | |
Insert fuel injectors for cylinders 5 to 8 (Y76/5 Y76/6, Y76/7, Y76/8) into cylinders in which they were previously installed. Engine damage can occur otherwise. |
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| 24 | Attach fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) to the rail (10) and fasten with clips (11). | ||
| 25 | Read off and note down injector injection quantity adjustment coding on fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | When installing new fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | |
| 26 | Insert rail (10) with fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) into left cylinder head. | ||
| 27 | Tighten screws (9). | Screw in screws (9) alternately by, in each case, half a turn. Start in center of rail (10) and work outwards. Rail (10) will otherwise be damaged. |
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| *BA07.52-P-1001-01J | |||
| 28.1 | Connect electrical connector of left fuel pressure and temperature sensor (B42/2) until it locks. | Where rail (10) is reused. | |
| 28.2 | Install left fuel pressure and temperature sensor (B42/2). | When replacing rail (10). | |
| AR07.04-P-0201MNL | |||
| 29 | Connect and lock electrical connectors (8) of the fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | ||
| 30 | Connect and lock electrical connector of the cylinder 5 intake CAMTRONIC actuator (Y49/15) and the cylinder 8 intake CAMTRONIC actuator (Y49/17). | ||
| 31 | Install bleed line (5) at cylinder head cover. | *BA01.20-P-1001-01J | |
| 32 | Install filler neck for engine oil at cylinder head cover. | AR01.40-P-0004MNL | |
| *BA01.20-P-1006-01J | |||
| 33 | Install soundproofing (4) at rail (10). | ||
| 34 | Install low-pressure line (2) with service connection. | AR07.03-P-1121MNL | |
| 35 | Install crash plate (3). | *BA07.02-P-1002-01E | |
| 36 | Screw dust cap onto service connection and tighten. | *BA07.03-P-1005-01H | |
| 37 | Install cover (1). | *BA00.10-P-1002-01A | |
| 38 | Install left high-pressure line. | AR07.03-P-1001MNL | |
| 39 | Read out and delete fault memory. | ||
| AD00.00-P-2000-04B | |||
| 40 | Store injector injection quantity adjustment coding in ME-SFI [ME] control unit (N3/10). | When installing new fuel injectors for cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | |
| AD00.00-P-2000-04B | |||
| 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 | |
| 41 | Check fuel high pressure circuit for leaktightness. | AR07.03-P-1010-04MM | |
| AD00.00-P-2000-04B | |||
| 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 | |
| 42 | Carry out engine test run and check engine for proper operation and leak tightness. | ||
| 43 | Install upper engine cover. |
HEADLESS SCREWS: BOLTS AND NUTS, COARSE-PITCH THREAD
| Number | Designation | Model all (4xWD, CAR, smart) | |||
|---|---|---|---|---|---|
| BA00.10-P-1002-01A | M6 | 8.8 | Galvanized | Nm | 9 |
| Phosphated | Nm | 9 | |||
| 10.9 | Galvanized | Nm | 13 | ||
| Phosphated | Nm | 12 | |||
| 12.9 | Galvanized | Nm | 16 | ||
| Phosphated | Nm | 14 | |||
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA01.20-P-1001-01J | Bolt, vent line to cylinder head cover/turbocharger | Nm | 9 |
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA01.20-P-1006-01J | Bolt, filler neck to cylinder head cover | Nm | 9 |
INJECTION PUMP, HIGH-PRESSURE FUEL PUMP
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA07.02-P-1002-01E | Bolt, shield to cylinder head/cylinder head cover | Nm | 10 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA07.03-P-1005-01H | Dust protection cap to service connection | Nm | 1 |
FUEL DISTRIBUTOR
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA07.52-P-1001-01J | Bolt, fuel distributor to cylinder head cover | Nm | 9 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |