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

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ENGINE 157, 278 in MODEL 212, 218 

ENGINE 278 in MODEL 207 

Shown on model 218.373 

Fig 1: Rail Remove/Install Components - Shown On Model 218.373
G09974603DANGERDANGERIMPORTANTREMOVINGNOTESTORQUE SPECIFICATIONSPECIAL TOOLNOTESNOTESNOTESIMPORTANTIMPORTANTIMPORTANTIMPORTANTSPECIAL TOOLCLEANNOTESINSPECTNOTESINSTALLINGSPECIAL TOOLIMPORTANTIMPORTANTIMPORTANTNOTESTORQUE SPECIFICATIONNOTESTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONREFER 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 upper engine covers    
3 Remove air filter housing    
4 Remove insulation on rail (1)    
5 Remove ME-SFI [ME] control unit   AR07.08-P-7008ELB 
6 Disconnect electrical connection at fuel pressure and temperature sensor When removing the right rail (1)  
7 Detach engine wiring harness from rail (1) and fuel injectors (Y76)   AR01.00-P-2410-02ELB
8 Relieve fuel pressure over diagnostic socket   AR07.03-P-1460-01VA 
    TORQUE SPECIFICATION Protective cap on service valve *BA07.03-P-1007-01E 
    SPECIAL TOOL Pressure hose Figure
9 Remove fuel pressure in fuel high-pressure circuit   AR07.03-P-1460-02MM 
10 Remove high-pressure lines for high-pressure pumps on rail (1) NOTES Do not kink or bend high-pressure lines.
This is to avoid leaks and damage if the high-pressure lines are possibly used again (after successfully passing checking).		  
11 Remove high-pressure line between rails (1) NOTES Do not kink or bend high-pressure lines. This is to avoid leaks and damage if the high-pressure lines are possibly used again (after successfully passing checking).  
12 Remove screw/bolts (1s) from rail (1) NOTES Remove screw/bolts (1s) for removal of the rail (1) alternately by respectively turning half a revolution from the center outwards.
Damage to the rail (1) can occur otherwise.		  
13 Remove hold-down device (3) between rail (1) and fuel injectors (Y76)    
14 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.  
15 Detach rail (1) from fuel injectors (Y76)    
16 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 When reusing the fuel injectors they (Y76) must be inserted into the cylinder in which it was previously installed.
IMPORTANT Fuel injectors (Y76) must be removed since the rail (1) may only jointly be installed with the fuel injectors (Y76).		 AR07.03-P-0004ELB
    In case of jammed fuel injectors (Y76):
↓
Remove injection nozzles		  
      AR07.03-P-0004-03MM
    SPECIAL TOOL Puller Figure
CLEAN Clean     
17 Clean fuel connections on fuel injectors (Y76) NOTES During cleaning the fuel connections must be held downwards.
Dirt will get into the openings otherwise.		  
INSPECT Check     
18 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     
19 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 Figure
20 Put fuel injectors (Y76) into rail (1) and fasten in place using the hold-down tools (3) IMPORTANT When reusing the fuel injectors they (Y76) 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).		  
21 Replace seal (2) on spilling of the rail (1)    
22 Insert rail (1) with fuel injectors (Y76) into the cylinder head    
23 Screw in screw/bolts (1s) NOTES Screw in screw/bolts (1s) alternately each by half a revolution. Begin in the middle 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 
24 Mount high-pressure line on rail (1) and high-pressure pump   AR07.03-P-1010-02MMB 
    NOTES Do not kink or bend high-pressure lines. Otherwise leaks and damage may occur.  
    TORQUE SPECIFICATION Union nut, fuel line to fuel distributor *BA07.03-P-1001-01E 
    TORQUE SPECIFICATION Union nut, fuel line to high-pressure pump *BA07.03-P-1002-01E 
    TORQUE SPECIFICATION Bolt, fuel line service valve to cylinder head cover *BA07.03-P-1003-01E 
    TORQUE SPECIFICATION Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head *BA07.03-P-1004-01E 
    TORQUE SPECIFICATION Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase *BA07.03-P-1005-01E 
    TORQUE SPECIFICATION Bolt, fuel line clamp to charge air distribution line *BA07.03-P-1006-01E 
25 Mount engine wiring harness from rail (1) and fuel injectors (Y76)   AR01.00-P-2410-02ELB
26 Connect electrical connection at fuel pressure and temperature sensor When removing the right rail (1)  
27 Install ME-SFI [ME] control unit   AR07.08-P-7008ELB 
28 Install insulation on rail (1)    
29 Install air filter housing    
30 Install upper engine covers    
31 Mount ground line on battery   AR54.10-P-0003EW
32 Read out fault memory using the diagnostic system and clear if necessary    
REFER TO SELF-DIAGNOSTIC SYSTEMS     AD00.00-P-2000-04A
INSPECT Check     
33 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
34 Carry out an engine test run, checking the engine for proper operation and leaktightness    
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1001-01E Union nut, fuel line to fuel distributor Nm 22 22
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1002-01E Union nut, fuel line to high-pressure pump Nm 22 22
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1003-01E Bolt, fuel line service valve to cylinder head cover Nm 9 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1004-01E Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head Nm 14 14
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1005-01E Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase Nm 9 9
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1006-01E Bolt, fuel line clamp to charge air distribution line Nm 5 5
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation ENGINE 157 ENGINE 278
BA07.03-P-1007-01E Protective cap on service valve Plastic Nm 2 2
Metal Nm 15 15
FUEL DISTRIBUTOR

Number Designation ENGINE 157 ENGINE 278
BA07.52-P-1001-01G Screw/bolt, fuel distributor to cylinder head cover Nm 9 9
Fig 2: Identifying Drift (278 589 01 15 00)
G09974604Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Pressure Hose (119 589 04 63 00)
G09974605Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Puller (278 589 00 33 00)
G09974606Courtesy 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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