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Remove/install rail - AR07.03-P-1010EL

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ENGINE 276 in MODEL 212, 218 

MODIFICATION NOTES

24.9.14 Union nut, fuel line to high-pressure pump   BA07.03-P-1002-01D
24.9.14 Union nut, fuel line to fuel distributor   BA07.03-P-1001-01D

Shown on model 212.080 

Fig 1: Rail Remove/Install Components - Shown On Model 212.080 (1 Of 3)
G09974596Courtesy of MERCEDES-BENZ USA
Fig 2: Rail Remove/Install Components - Shown On Model 212.080 (2 Of 3)
G09974597Courtesy of MERCEDES-BENZ USA
Fig 3: Rail Remove/Install Components - Shown On Model 212.080 (3 Of 3)
G09974598DANGERDANGERIMPORTANTREMOVINGNOTESTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONSPECIAL TOOLNOTESIMPORTANTIMPORTANTIMPORTANTSPECIAL TOOLPROGRAM HEATING (2ND CUT-IN TIME)NOTESINSPECTNOTESINSTALLINGSPECIAL TOOLSPECIAL TOOLIMPORTANTIMPORTANTIMPORTANTNOTESTORQUE SPECIFICATIONTORQUE SPECIFICATIONNOTESIMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONIMPORTANTREFER TO SELF-DIAGNOSTIC SYSTEMSINSPECTDANGERCourtesy of MERCEDES-BENZ USA
DANGER Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof. No parts of the body or limbs should be within the operating area when the components are moving. AS00.00-Z-0011-01A
DANGER 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
IMPORTANT General information on work on gasoline direct injection system   AH07.00-P-2000-01A
REMOVING Remove     
1 Detach ground line from battery   AR54.10-P-0003EW
NOTES Notes on battery   AH54.10-P-0001-01A
2 Remove center section of the bulkhead (78) ENGINE 276 in MODEL 212, 218  
ENGINE 276.8 in MODEL 212
ENGINE 276.9 in MODEL 212.095/195		 AR61.25-P-6600EW
3.1 Remove air filter housing ENGINE 276.9 in MODEL 212, 218
When removing the right rail (1)		  
    TORQUE SPECIFICATION Bolt, air filter to air intake pipe support brace *BA09.10-P-1002-01M 
    TORQUE SPECIFICATION Bolt, air filter to cylinder head cover *BA09.10-P-1001-01M 
3.2 Remove both air filter housings ENGINE 276.8 in MODEL 212, 218 When removing the left or right rail (1)  
      AR09.10-P-1150ELS
4 Remove connecting flange of the intake manifold ENGINE 276.9 in MODEL 212, 218 AR09.20-P-1961EL
5 Remove crash plate and insulation on the high-pressure pump   AR07.02-P-1020EL
6 Relieve fuel pressure over diagnostic socket   AR07.03-P-1460-01VA 
    TORQUE SPECIFICATION Cap on service connection *BA07.03-P-1007-01D 
    SPECIAL TOOL Pressure hose Fig 5
7 Remove fuel pressure in fuel high-pressure circuit   AR07.03-P-1460-02MM 
8 Detach high-pressure line between rail (1) and high-pressure pump    
9 Detach fuel line (low pressure) at high-pressure pump    
10 Disconnect electrical connection on RH exhaust camshaft Hall sensor (B6/7) ENGINE 276.9 in MODEL 212
ENGINE 276.9 in MODEL 218		  
11 Disconnect electrical connection on fuel pressure and temperature sensor (B4/25)    
12 Detach engine wiring harness on the rail (1). ENGINE 276.9 in MODEL 212, 218 AR01.00-P-2410-02EL
    ENGINE 276.8 in MODEL 212, 218 AR01.00-P-2410-02ELS
13 Remove support (4) for the intake manifold ENGINE 276.9 in MODEL 212, 218  
14 Remove screws/bolts (1s) NOTES Unscrew screw/bolts (1s) alternately each by half a revolution. Begin in the center of the rail (1) and work outwards.
Damage to the rail (1) can occur otherwise.		  
15 Remove hold-down tool (3) between rail (1) and fuel injectors (Y76)    
16 Mark fuel injectors (Y76) relative to the respective cylinder IMPORTANT When reusing the fuel injectors (Y76) they must be inserted into the cylinder in which it was previously installed.  
17 Detach rail (1) from fuel injectors (Y76)    
18 Remove fuel injectors (Y76) IMPORTANT Oil which comes out during disassembly of the rail (1) or from the fuel injectors (Y76) is safe. The rail (1) or the fuel injectors (Y76) can be re-used.
IMPORTANT All fuel injectors (Y76) must be pulled out since the rail (1) may only jointly be installed with the fuel injectors (Y76).		 AR07.03-P-0004EL
    In case of jammed fuel injectors (Y76):
↓
Remove fuel injectors (Y76).		  
      AR07.03-P-0004-03MM
    SPECIAL TOOL Puller Fig 6
PROGRAM HEATING (2ND CUT-IN TIME) Clean     
19 Clean fuel connections on fuel injectors (Y76) NOTES During cleaning the fuel connections must be held downwards.
This ensures that no dirt gets into the openings.		  
    Assembly cleaner *BR00.45-Z-1028-04A 
INSPECT Check     
20 Check high-pressure line and replace if necessary   AR07.03-P-1010-03MM 
    NOTES The sealing cone for high-pressure lines must be checked before assembly.
Do this to avoid leaks and damage.		  
    Assembly cleaner *BR00.45-Z-1028-04A 
INSTALLING Install     
21 Replace sealing packages for the fuel injectors (Y76) on rail (1)   AR07.03-P-0004-02MM
    Assembly cleaner *BR00.45-Z-1028-04A 
    SPECIAL TOOL Drift Fig 4
22 Replace sealing rings and seals (2) on the fuel injectors (Y76)   AR07.03-P-0004-01MM
    Assembly cleaner *BR00.45-Z-1028-04A 
    SPECIAL TOOL Assembly tool Fig 7
23 Replace seal (2) on spilling of the rail (1)    
24 Insert fuel injectors (Y76) into rail (1) and fasten in place using the hold-down tools (3) IMPORTANT When reusing the fuel injectors (Y76) they must be inserted into the cylinder in which it was previously installed.
IMPORTANT Fuel injectors (Y76) may only be installed again in combination with the rail (1) (as a whole).
IMPORTANT Replace hold-down tool (3).		  
25 Insert rail (1) with fuel injectors (Y76) into the cylinder head    
26 Screw in screw/bolts (1s) NOTES Screw in screw/bolts (1s) alternately each by half a revolution. Begin in the center of the rail (1) and work outwards.
Damage to the rail (1) can occur otherwise.		  
    TORQUE SPECIFICATION Screw/bolt, fuel distributor to cylinder head cover *BA07.52-P-1001-01G 
27 Install support (4) for the intake manifold ENGINE 276.9 in MODEL 212, 218  
28 Mount engine wiring harness on rail (1) and fuel injectors (Y76) ENGINE 276.9 in MODEL 212, 218 AR01.00-P-2410-02EL
    ENGINE 276.8 in MODEL 212, 218 AR01.00-P-2410-02ELS
29 Connect electrical connection on fuel pressure and temperature sensor (B4/25) When installing left rail (1)  
30 Connect electrical connection on RH exhaust camshaft Hall sensor (B6/7) ENGINE 276 (except 276.8) in MODEL 212
ENGINE 276 (except 276.8) in MODEL 218
When installing right rail (1)		  
31 Mount low-pressure line at high-pressure pump TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01D 
32 Mount high-pressure line on rail (1) and high-pressure pump   AR07.03-P-1010-02MMA 
    NOTES Do not kink or bend high-pressure line and low-pressure line.
Do this to avoid leaks and damage.
IMPORTANT The work instructions absolutely must be observed for assembly work.		  
    TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01D 
    TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01D 
33 Install crash plate and insulation on the high-pressure pump   AR07.02-P-1020EL
34 Install connecting flange of the intake manifold   AR09.20-P-1961EL
35.1 Install air filter housing ENGINE 276.9 in MODEL 212, 218
When installing right rail (1)		  
    TORQUE SPECIFICATION Bolt, air filter to air intake pipe support brace *BA09.10-P-1002-01M 
    TORQUE SPECIFICATION Bolt, air filter to cylinder head cover *BA09.10-P-1001-01M 
35.2 Install both air filter housing ENGINE 276.8 in MODEL 212, 218 When installing the left or right rail (1)  
      AR09.10-P-1150ELS
36 Install center section of the bulkhead (78) ENGINE 276.8 in MODEL 212, 218
ENGINE 276.9 in MODEL 212.095/195		  
ENGINE 276.8 in MODEL 212
ENGINE 276.9 in MODEL 212.095/195
IMPORTANT Ensure correct seating of the center section of the bulkhead (78).		 AR61.25-P-6600EW
37 Mount ground line on battery   AR54.10-P-0003EW
38 Read out fault memory using the diagnostic system and clear if necessary    
REFER TO SELF-DIAGNOSTIC SYSTEMS     AD00.00-P-2000-04A
INSPECT Check     
39 Check fuel high-pressure circuit for leaktightness   AR07.03-P-1010-04MM 
DANGER 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
40 Carry out an engine test run, checking the engine for proper operation and leaktightness    
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1001-01D Union nut, fuel line to fuel distributor Stage 1 Nm 15
Stage 2 ∠° 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1002-01D Union nut, fuel line to high-pressure pump Stage 1 Nm 15
Stage 2 ∠° 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 276
BA07.03-P-1007-01D Cap on service connection Plastic Nm 2
Metal Nm 15
FUEL DISTRIBUTOR

Number Designation ENGINE 276
BA07.52-P-1001-01G Screw/bolt, fuel distributor to cylinder head cover Nm 9
AIR FILTER

Number Designation ENGINE 276.9
BA09.10-P-1001-01M Bolt, air filter to cylinder head cover Nm 9
AIR FILTER

Number Designation ENGINE 276.9
BA09.10-P-1002-01M Bolt, air filter to air intake pipe support brace Nm 9
Fig 4: Identifying Drift (278 589 01 15 00)
G09974599Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Pressure Hose (119 589 04 63 00)
G09974600Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Puller (278 589 00 33 00)
G09974601Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Assembly Tool (272 589 00 43 00)
G09974602Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
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