Remove/Install Right Fuel Rail With Injectors - AR07.03-P-1051MNO

Engine 176 in model 167

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Shown on model 222.983

Courtesy of MERCEDES-BENZ USA

	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	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
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Remove
1	Remove right high-pressure line.		AR07.03-P-1002MNO
2	Detach electrical wiring harness (2) with guide and place to one side.
3	Remove vacuum line (3) from vacuum pump and place to one side.
4	Remove soundproofing (4) at rail (6).
5	Remove right low-pressure line.		AR07.03-P-1121MNO
6	Release and disconnect electrical connector o cylinder 2 intake CAMTRONIC actuator (Y49/11).
7	Unlock and disconnect the electrical connectors (9) of the fuel injectors of cylinders 1 and 4 (Y76/1, Y76/4).
8	Mark fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) relative to respective cylinder.	When reusing fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4).
9	Remove screws (10).	Remove screw/bolts (10) alternately each by half a revolution. Start in center of rail (6) and work outwards. Rail (6) will otherwise be damaged.
10	Remove rail (6) from fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) and seal openings with suitable stop plugs.	Record plug	Fig 2
11	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
		Puller	Fig 4
		Plug	Fig 1
	Check
12	Check fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) for external damage.	When reusing fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4). If damage is present, ↓ Replace respective affected fuel injector.
13	Check connection of fuel line at rail (6) for damage.	If connection on rail (6) is damaged: ↓ Replace rail (6).
14	Check right high-pressure line for damage.	Commercially available devices/tools Vernier caliper	AR07.03-P-1010-03MNO
		Assembly cleaner If damage to sealing cone exists ↓ Replace right high-pressure line.	*BR00.45-Z-1028-04A
			AR07.03-P-1002MNO
	Install
15	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).
16	Clean fuel connections at fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4).	For cleaning the fuel connections, hold downwards. Failure of the fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) will occur otherwise. If fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4), install this immediately after removing the transport protective cap. Leaks can occur otherwise.
		Assembly cleaner	*BR00.45-Z-1028-04A
17	Replace sealing packages of fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) at rail (6).		AR07.03-P-0004-02MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Drift	Fig 5
18	Install new sealing rings 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
		Assembly tool	Fig 3
19	Assign fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) to corresponding cylinders and clean injector well bores.	When reusing fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4).
		When reusing fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4), insert them into cylinder in which they were installed previously. Engine damage can occur otherwise.
20	Install fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) on rail (6) and secure them with new clips.
21	Insert rail (6) with fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4) in right cylinder head.
22	Tighten bolts (10).	Screw in screw/bolts (10) alternately each by half a revolution. Start in center of rail (6) and work outwards. Rail (6) will otherwise be damaged.
		Bolt, fuel distributor to cylinder head cover	*BA07.52-P-1001-01J
23.1	Connect electrical connection to fuel pressure and temperature sensor on right (B42/1).	Where rail (6) is reused.
23.2	Install new fuel pressure and temperature sensor on right (B42/1).	When installing a new rail (6).
			AR07.04-P-0202MNO
24	Connect electrical connectors (9) of fuel injectors of cylinders 1 to 4 (Y76/1, Y76/2, Y76/3, Y76/4).
25	Connect electrical connector of cylinder 2 intake CAMTRONIC actuator (Y49/11) and cylinder 3 intake CAMTRONIC actuator (Y49/13).
26	Attach right low-pressure line to fuel pump.		AR07.03-P-1121MNO
27	Install soundproofing (4) on rail (6).
28	Attach vacuum line (3) to vacuum pump.
29	Position electrical wiring harness (2) with guide and fix in place.
30	Install right high-pressure line.		AR07.03-P-1002MNO
		Only install upper engine cover after leak test of high-pressure fuel circuit.
31	Store injector injection quantity adjustment coding in ME-SFI [ME] control unit (N3/10).
			AD00.00-P-2000-06ME
	Check
32	Check fuel high-pressure circuit for leak tightness.		AR07.03-P-1010-04MM
			AD00.00-P-2000-06ME
	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
33	Perform engine test run. While doing so, check engine for proper operation and leak tightness
	Install
34	Install upper engine cover.
			AP01.10-P-2405-01M