Remove/Install Left Rail With Fuel Injectors - AR07.03-P-1050MNM
Engine 177 in model 217, 222
| 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 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 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 | |
| Notice | Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | |
| Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | AH00.00-P-0015-01CW | ||
| General information on work on gasoline direct injection system | AH07.00-P-2000-01A | ||
| Remove | |||
| 1 | Remove left high-pressure line | AR07.03-P-1001MNM | |
| 2 | Remove left-hand air filter housing | AR09.10-P-1151MNM | |
| 3 | Remove bracket of purge valves | AR15.12-P-2148MNM | |
| 4 | Remove screws/bolts (8) and remove engine lifting lug (9) | ||
| 5 | Disconnect engine wiring harness | AR15.18-P-1000-07MNM | |
| 6 | Clean area surrounding the service connection (4) | Assembly cleaner | *BR00.45-Z-1028-04A |
| 7 | Remove fuel line (3) at service connection (4) | ||
| 8 | Seal openings of the fuel line (3) and service connection (4) with suitable stop plugs | Fig 2 | |
| 9 | Remove left low-pressure line with service connection (4), and place to one side with hose connection connected | AR07.03-P-1121MNM | |
| 10 | Remove soundproofing (2) at rail (7) | ||
| 11 | Remove bleed line (6) from cylinder head cover and seal openings with suitable stop plugs | Fig 2 | |
| 12 | Remove brackets (11) | ||
| 13 | Remove screws (10) | Otherwise, damage to the rail (7) occurs. |
|
| 14 | Remove rail (7) 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 of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) relative to respective cylinder | On reuse of fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | |
| 16 | Pull fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) out of cylinder head, and seal injector shaft holes with suitable stop plugs | AR07.03-P-0004-03MM | |
| Fig 1 | |||
| Fig 4 | |||
| 17 | Check fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) for external damage, and replace if necessary | On reuse of fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | |
| Install | |||
| 18 | Clean fuel connections at fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) | Leaks can occur otherwise. Otherwise, failure of fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) occurs. Assembly cleaner |
*BR00.45-Z-1028-04A |
| 19 | Replace sealing packages of fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) on rail (7) | AR07.03-P-0004-02MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 6 | |||
| 20.1 | Replace sealing rings (12, 13) on the fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) | On reuse of fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | |
| 20.2 | Install new sealing rings (12, 13) on fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) | On replacing fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | |
| 21 | Install new sealing rings (14) on fuel injectors of 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 | |||
| 22 | Install fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) in rail (7), and fasten with new brackets (11) | Engine damage will occur otherwise. |
|
| 23 | Read off injector injection quantity adjustment coding on fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) and note | On replacing fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | |
| 24 | Insert rail (7) with fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8) into left cylinder head | ||
| 25 | Tighten screws/bolts (10) | Otherwise, damage to the rail (7) occurs. |
*BA07.52-P-1001-01J |
| 26 | Install new left fuel pressure and temperature sensor (B42/2) on rail (7) | On replacing rail (7). | AR07.04-P-0201MNM |
| 27 | Attach vent line (6) to cylinder head cover | *BA01.20-P-1001-01J | |
| 28 | Install soundproofing (2) on rail (7) | ||
| 29 | Attach left low-pressure line with service connection (4) | AR07.03-P-1121MNM | |
| 30 | Check connection of fuel line (3) for damage | If sealing cone is damaged ↓ Replace fuel line (3). |
|
| 31 | Attach fuel line (3) to service connection (4) | *BA07.03-P-1006-01H | |
| Fig 5 | |||
| 32 | Screw dust cap onto service connection (4) and tighten | *BA07.03-P-1005-01H | |
| 33 | Attach engine wiring harness | AR15.18-P-1000-07MNM | |
| *BA15.18-P-1003-01G | |||
| *BA15.10-P-1003-05F | |||
| *BA00.10-P-1002-04A | |||
| 34 | Install engine suspension lug (9), and tighten screws/bolts (8) | *BA01.30-P-1003-01N | |
| 35 | Install bracket of purge valves | AR15.12-P-2148MNM | |
| 36 | Install left-hand air filter housing | AR09.10-P-1151MNM | |
| 37 | Install left high-pressure line | AR07.03-P-1001MNM | |
| 38 | Read out and erase fault memory | ||
| AD00.00-P-2000-04B | |||
| 39 | Store injector injection quantity adjustment coding in engine management control unit | On replacing fuel injectors of cylinders 5 to 8 (Y76/5, Y76/6, Y76/7, Y76/8). | |
| AD00.00-P-2000-04B | |||
| 40 | Check fuel high-pressure circuit for leaktightness | AR07.03-P-1010-04MM | |
| 41 | Perform an engine test run and check engine for proper operation and leaktightness | ||
| 42 | Install upper engine cover |
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-P-1002-04A | M6 X 1 | Nm | 9 | 13 |
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER
| Number | Designation | Engine 177.9 | |
|---|---|---|---|
| BA01.20-P-1001-01J | Bolt, vent line to cylinder head cover/turbocharger | Nm | 9 |
CYLINDER HEAD
| Number | Designation | Engine 177 | ||
|---|---|---|---|---|
| BA01.30-P-1003-01N | Bolt, heat shield/rear lifting eye to cylinder head | M6 | Nm | 9 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA07.03-P-1005-01H | Dust protection cap to service connection | Nm | 1 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA07.03-P-1006-01H | Union nut, fuel hose to diagnostic socket/fuel line | Nm | 24 |
FUEL DISTRIBUTOR
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA07.52-P-1001-01J | Bolt, fuel distributor to cylinder head cover | Nm | 9 |
GROUND STRAP
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA15.10-P-1003-05F | Bolt, engine wiring harness ground to cylinder head cover | Nm | 9 |
ENGINE WIRING HARNESS
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA15.18-P-1003-01G | Screw, cable duct to cylinder head cover/charge air cooler/heat shield, right | Nm | 9 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |