Remove/Install Fuel Rail - AR07.03-P-1010MFG

Engine 139 in model 118, 177, 247

MODIFICATION NOTES

16.08.2021

Tightening procedure added.

Operation step 38.

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

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 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 to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-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
	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
Notice	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Notice	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Notice	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Notice	Notes on coolant		AH20.00-P-2080-01KOA
	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	Relieve fuel pressure using diagnostic system.
			AD00.00-P-2000-06MFA
			AR07.00-P-0003-01MFA
2	Remove upper engine cover.
			AP01.10-P-2405-01K
3	Remove ground line at on-board electrical system battery (G1).		AR54.10-P-0003MFA
4	Release residual fuel pressure.		AR07.03-P-1460-02MM
5	Remove ignition coils.		AR15.12-P-2003MFG
6	Remove spark plugs and seal openings in cylinder head with suitable stop plugs.
			AP15.10-P-1580J
		Plug	Fig 1
7	Unscrew screws (6).
8	Remove lines (9) from cable duct (8).
9	Remove vacuum line (7) from cable duct (8).
10	Release and disconnect electrical connectors of fuel injectors (Y76/1 to Y76/4).
11	Remove engine wiring harness with cable duct (5) from rail (1) and place together with cable duct (8) to one side.	Do not kink, subject lines to tension. Otherwise damage will occur. Secure engine wiring harness outside of working area with cable tie.
12	Remove screws (12) of coolant return line (13) at cylinder head cover.
13	Remove coolant return line (13) from coolant expansion reservoir.		AR20.20-P-7441-01RQ
14	Seal openings with suitable stop plugs and place coolant return line (13) to one side.	Record plug	Fig 4
15	Remove noise insulation (14).
16	Remove high-pressure line (3)..		AR07.16-P-1002MFG
		Do not kink or bend high-pressure line (3). Otherwise leaks and damage can occur.
17	move screws (1s).
18	Remove clamps (2) between rail (1) and fuel injectors (Y76/1 to Y76/4).
19	Remove rail (1) from fuel injectors (Y76/1 to Y76/4) and seal openings with suitable stop plugs.	Ensure utmost cleanliness. Otherwise, leaks and malfunctions occur.
		Record plug	Fig 4
20	Mark fuel injectors (Y76/1 to Y76/4) relative to corresponding cylinder.	Only where fuel injectors (Y76/1 to Y76/4) are reused.
21	Remove sealing packages of fuel injectors (Y76/1 to Y76/4) at rail (1).		AR07.03-P-0004-02MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Drift	Fig 7
22	Remove fuel injectors (Y76/1 to Y76/4) from cylinder head and seal injector well bores with suitable stop plugs.		AR07.03-P-0004-03MM
		Plug	Fig 1
		Puller	Fig 6
23	Remove sealing rings (17, 18).
24	Remove sealing rings (19).		AR07.03-P-0004-01MM
		Assembly tool	Fig 5
	Check
25	Check fuel injectors (Y76/1 to Y76/4) for damage.	If there are problems, ↓ Replace fuel injectors (Y76/1 to Y76/4).
	Clean
26	Clean fuel connections of fuel injectors (Y76/1 to Y76/4).	Hold fuel connections downwards during cleaning. Fuel injectors (Y76/1 to Y76/4) will otherwise be damaged.
		Assembly cleaner	*BR00.45-Z-1028-04A
27	Remove stop plugs of injector well bores and spark plug bores.	Plug	Fig 1
28	Connect connecting hose from adapter set to vacuum cleaner and insert connecting hose into spark plug bore.	Serves to suction off cleaning abrasion in parallel to cleaning process.
		Adapter	Fig 3
29	Clean combustion residues from injector well bores in cylinder head and extract combustion residues.	Clean bores of injector tips in cylinder head with cylinder brush. Seals of fuel injectors (Y76/1 to Y76/4) will otherwise be damaged during installation. Rotational speed and cleaning period must be complied with. Stock removal at cylinder head will otherwise occur and thus damage that will result in cylinder head replacement. Suction off cleaning abrasion in parallel to cleaning process. Dirt particles will otherwise get into combustion chamber, which results in engine damage. Insert cylinder brush in a suitable cordless screwdriver, clean at a rotational speed < 500 rpm per bore for 4 s and then blow out injector well with compressed air.
		Adapter	Fig 3
		Cylinder brush	Fig 2
	Install
30	Remove connecting hose from spark plug bore.	Adapter	Fig 3
31	Install pressure and temperature sensor.	When replacing the rail (1).
			AR07.04-P-0091MFG
		Replace pressure and temperature sensor.
32	Install sealing rings (17, 18).	Replace sealing rings (17, 18).
33	Install sealing rings (19).		AR07.03-P-0004-01MM
		Replace sealing rings (19).
		Assembly cleaner	*BR00.45-Z-1028-04A
		Assembly tool	Fig 5
34	Install sealing packages of fuel injectors (Y76/1 to Y76/4) at rail (1).		AR07.03-P-0004-02MM
		Replace sealing packages of fuel injectors (Y76/1 to Y76/4).
		Assembly cleaner	*BR00.45-Z-1028-04A
		Drift	Fig 7
35	Remove stop plugs and insert fuel injectors (Y76/1 to Y76/4) in rail (1).	Ensure rail (1) is correctly seated relative to fuel injectors (Y76/1 to Y76/4). Sealing packages of fuel injectors (Y76/1 to Y76/4) will otherwise be damaged. Where fuel injectors (Y76/1 to Y76/4) are reused, observe the markings applied during removal. Engine damage will occur otherwise. Where fuel injectors (Y76/1 to Y76/4) will be replaced, immediately install these after removal of transport protective caps. Leaks can occur otherwise.
		Record plug	Fig 4
36	Install clamps (2) between rail (1) and fuel injectors (Y76/1 to Y76/4).	Install new clips (2). Fuel injectors (Y76/1 to Y76/4) are installed together with rail (1).
37	Install fuel injectors (Y76/1 to Y76/4) together with rail (1) in injector well bores in cylinder head.
38	Screw in screws (1s).
	Fuel distributor tightening procedure		GF07.03-P-2107-01MFG
		Screw/bolt, fuel distributor to cylinder head cover	*BA07.52-P-1001-01H
39	Install high-pressure line (3).		AR07.16-P-1002MFG
		Do not kink or bend high-pressure line (3). Otherwise leaks and damage can occur.
40	Install noise insulation (14).
41	Remove stop plugs of coolant return line (13).	Record plug	Fig 4
42	Attach coolant return line (13) to the coolant expansion reservoir.		AR20.20-P-7441-01RQ
43	Screw in screws (12) of coolant return line (13) at cylinder head cover.	Bolt, coolant line to cylinder head cover	*BA01.20-P-1009-01R
44	Install engine wiring harness with cable duct (5, 8).	Do not kink, subject lines to tension. Otherwise damage will occur.
45	Connect and lock electrical connectors of fuel injectors (Y76/1 to Y76/4).
46	Attach vacuum line (7) to cable duct (8).
47	Attach lines (9) to cable duct (8).
48	Screw in screws (6).	Screw, engine cable duct to cylinder head cover/charge-air distributor/oil separator/high-pressure pump shielding	*BA01.20-P-1010-01R
49	Install spark plugs.
			AP15.10-P-1580J
		Do not install upper engine cover until after the leak test.
50	Install ignition coils.		AR15.12-P-2003MFG
51	Attach ground line to on-board electrical system battery (G1).		AR54.10-P-0003MFA
	Check
52	Check engine cooling system for leak tightness.		AR20.00-P-1010MFG
53	Check high-pressure fuel circuit for leaks.
			AD00.00-P-2000-06MFA
			AR07.03-P-1010-04MM
54	Store injector quantity compensation (coding) in motor control module (MCM).	When replacing fuel injectors (Y76/1 to Y76/4).
			AD00.00-P-2000-06MFA
55	Read out and delete fault memory.
			AD00.00-P-2000-06MFA
56	Perform engine test run. While doing so, check engine for proper operation and leak tightness.
57	Install upper engine cover.
			AP01.10-P-2405-01K