Remove/Install Right Fuel Rail With Fuel Injectors - AR07.03-P-1051XGA
Engine 176 in model 463
as of model year 2019
| 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 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 | |
| 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 | |
| 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 right high-pressure line | AR07.03-P-1002XGA | |
| 2 | Remove right low-pressure line from fuel high- pressure pump and right cylinder head cover and place outside working area with hose connection attached | AR07.03-P-1121XGA | |
| 3 | Remove noise insulation (1) | ||
| 4 | Release and disconnect electrical connector of cylinder 2 intake CAMTRONIC actuator (Y49/11) | ||
| 5 | Release and disconnect electrical connectors (4) of fuel injectors of cylinders 1 and 4 (Y76/1, Y76/4) | ||
| 6 | Remove holders (10) between rail (3) and fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) | ||
| 7 | Mark fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) in relation to the respective cylinder | When reusing the fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4). When reusing the fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4), they must be inserted into the cylinder in which they were installed before. Engine damage will occur otherwise. |
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| 8 | Unscrew screws (2) on rail (3) | Remove screws (2) alternately by half a revolution each. Start in center of rail (3) and work outwards. The rail (3) will otherwise be damaged. |
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| 9 | Remove rail (3) from fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) and seal openings with suitable stop plugs | Fig 3 | |
| 10 | Remove fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) from cylinder head and seal injector well bores with suitable stop plugs | AR07.03-P-0004-03MM | |
| Fig 1 | |||
| Fig 2 | |||
| 11 | Check fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) for damage and replace if necessary | When reusing the fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4). | |
| Install | |||
| 12 | Clean fuel connections on fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) | If fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) are replaced they must be installed immediately after the transport protection caps are removed. Leaks can occur otherwise. For cleaning the fuel connections, hold downwards. Otherwise, the fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) will fail. |
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| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 13 | Replace sealing packages of fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) on rail (3) | AR07.03-P-0004-02MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 4 | |||
| 14 | Replace sealing rings (11, 12) on fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) | ||
| 15 | Replace sealing rings (13) on fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) | AR07.03-P-0004-01MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 5 | |||
| 16 | Install fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) in the rail (3) and secure with holders (10) | When reusing the fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) they must be inserted into the cylinder in which they were installed before. Engine damage will occur otherwise. |
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| 17 | Read off injector injection quantity adjustment coding on fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) and note down | When replacing fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4). | |
| 18 | Insert rail (3) with fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) in right cylinder head | ||
| 19 | Tighten screws (2) on rail (3) | Screw in screws (2) alternately by half a revolution each. Start in center of rail (3) and work outwards. The rail (3) will otherwise be damaged. |
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| *BA07.52-P-1001-01J | |||
| 20 | Install right pressure and temperature sensor (B42/1) in rail (3) | When replacing the rail (3). | |
| AR07.04-P-0202XGA | |||
| 21 | Connect electrical connectors (4) on fuel injectors of cylinders 1 and 4 (Y76/1, Y76/4) until they lock | ||
| 22 | Connect electrical connector of cylinder 2 intake CAMTRONIC actuator (Y49/11) until it locks | ||
| 23 | Install noise insulation (1) | ||
| 24 | Attach right low-pressure line to right cylinder head cover and fuel high-pressure pump | AR07.03-P-1121XGA | |
| 25 | Install right high-pressure line | AR07.03-P-1002XGA | |
| 26 | Read out and erase fault memory | ||
| AD00.00-P-2000-04B | |||
| 27 | Store injector injection quantity adjustment coding in engine management control unit | When replacing fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4). | |
| AD00.00-P-2000-04B | |||
| 28 | Check fuel high-pressure circuit for leaktightness | AR07.03-P-1010-04MM | |
| AD00.00-P-2000-04B | |||
| 29 | Perform an engine test run and check engine for proper operation and leak tightness |
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 |