Remove/Install Low-Pressure Fuel Lines - AR07.03-P-1121MNL
Engine 176 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 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 | |
| Notice | Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | |
| 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/install | |||
| 1 | Disconnect battery ground line | AR54.10-P-0003LF | |
| 2 | Remove left-hand air filter housing | AR09.10-P-1151MNL | |
| 3 | Remove soundproofing (3) | ||
| 4 | Remove filler neck | AR01.40-P-0004MNL | |
| 5 | Remove covers (5) | *BA00.10-P-1002-01A | |
| 6 | Remove bleed line (6) from cylinder head cover | *BA01.20-P-1001-01J | |
| 7 | Relieve fuel pressure over diagnostic socket | AR07.03-P-1460-01MNL | |
| *BA07.03-P-1005-01H | |||
| Fig 3 | |||
| 8 | Clean area around left low-pressure line with service connection (7) | Assembly cleaner | *BR00.45-Z-1028-04A |
| 9 | Remove left low-pressure line with service connection (7) from fuel high-pressure pump (4) | *BA07.03-P-1001-01H | |
| Fig 2 | |||
| 10 | Remove fuel supply line from service connection, and seal openings with suitable stop plugs | *BA07.03-P-1006-01H | |
| Fig 1 | |||
| Fig 2 | |||
| 11 | Remove left low-pressure line with service connection (7) from cylinder head cover and bracket of coolant return line of exhaust gas turbochargers | *BA07.03-P-1004-01H | |
| 12 | Seal opening at fuel system high-pressure pump (4) with suitable stop plug | Fig 1 | |
| 13 | Check left low-pressure line with service connection (7) for damage | AR07.03-P-1120-01MNE | |
| Assembly cleaner If a problem arises ↓ Replace left low-pressure line with service connection (7). |
*BR00.45-Z-1028-04A | ||
| 14 | Remove left low-pressure line with service connection (7) and seal with suitable stop plugs | Leaks can occur otherwise. |
Fig 1 |
| 15 | Remove right air filter housing | AR09.10-P-1152MNL | |
| 16 | Remove soundproofing (2) | ||
| 17 | Remove covers (13) | *BA00.10-P-1002-04A | |
| 18 | Remove bleed line (12) from cylinder head cover | *BA01.20-P-1001-01J | |
| 19 | Clean area around right low-pressure line (11) | Assembly cleaner | *BR00.45-Z-1028-04A |
| 20 | Remove right low-pressure line (11) from fuel high-pressure pump (1) | *BA07.03-P-1001-01H | |
| Fig 2 | |||
| 21 | Remove right low-pressure line (11) from cylinder head cover | *BA07.03-P-1004-01H | |
| 22 | Seal openings on fuel high-pressure pump (1) with suitable stop plugs | Fig 1 | |
| 23 | Check right low-pressure line (11) for damage | AR07.03-P-1120-01MNE | |
| Assembly cleaner If a problem arises ↓ Replace right low-pressure line (11). |
*BR00.45-Z-1028-04A | ||
| 24 | Remove right low-pressure line (11) and seal with suitable stop plugs | Leaks can occur otherwise. |
Fig 1 |
| 25 | Remove charge air cooler | Right charge air cooler Engine 176 in model 217, 222with small lower coolant expansion reservoir for low-temperature circuit |
AR09.41-P-6828MNL |
| Left charge air cooler Engine 176 in model 217, 222 with small lower coolant expansion reservoir for low-temperature circuit | AR09.41-P-6827MNL | ||
| Right charge air cooler Engine 176 in model 217, 222 with large lower coolant expansion reservoir for low-temperature circuit | AR09.41-P-6828MNP | ||
| Left charge air cooler Engine 176 in model 217, 222 with large lower coolant expansion reservoir for low-temperature circuit |
AR09.41-P-6827MNP | ||
| 26 | Remove boots (8) from exhaust gas turbochargers | *BA01.20-P-1003-01J | |
| 27 | Remove boots (9) | *BA09.41-P-1002-01X | |
| 28 | Remove center low-pressure line (10) | *BA07.03-P-1004-01H | |
| 29 | Remove hoses from center low-pressure line (10) and seal openings of low-pressure line (10) with suitable stop plugs | Leaks can occur otherwise. |
Fig 1 |
| 30 | Install in the reverse order | ||
| 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 | |
| 31 | Perform an engine test run and check engine for proper operation and leak tightness | ||
| 32 | Install lower engine compartment paneling | AR61.20-P-1105LF | |
| 33 | 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 | |||
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 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-1003-01J | Clamp, boot to exhaust gas turbocharger/air filter | Nm | 1, 5 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 176 | |||
|---|---|---|---|---|---|
| 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 176 | |
|---|---|---|---|
| BA07.03-P-1004-01H | Bolt, fuel line clamp to engine/bracket | Nm | 9 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA07.03-P-1005-01H | Dust protection cap to service connection | Nm | 1 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA07.03-P-1006-01H | Union nut, fuel hose to diagnostic socket/fuel line | Nm | 24 |
CHARGE AIR LINE/CHARGE AIR COOLING
| Number | Designation | Engine 176 | |
|---|---|---|---|
| BA09.41-P-1002-01X | Bolt, clamp for charge air hose to charge-air distributor | Nm | 6 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |