Remove/install right rail - AR07.03-P-1012MNA

ENGINE 176 in MODEL 463

ENGINE 177 in MODEL 205

MODIFICATION NOTES

25.08.2016	Screw/bolt, shield plate to cylinder head	Motor 176	BA07.02-P-1002-01E
25.08.2016	Screw/bolt, shield plate to cylinder head	Motor 177.980	BA07.02-P-1002-01E

Shown on ENGINE 177

Fig 1: Right Rail Remove/Install Components - Shown On Engine 177 (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Right Rail Remove/Install Components - Shown On Engine 177 (2 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 3: Right Rail Remove/Install Components

Courtesy of MERCEDES-BENZ USA

Shown on ENGINE 176

Fig 4: Right Rail Remove/Install Components - Shown On Engine 176

Courtesy of MERCEDES-BENZ USA

Fig 5: Right Rail Remove/Install Components

Courtesy of MERCEDES-BENZ USA

	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 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
	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Remove
1	Detach ground line from battery	Engine 176 in model 463	AR54.10-P-0003GW
		Engine 177 in model 205	AR54.10-P-0003LW
2	Remove left and right air filter housing		AR09.10-P-1150MNA
3	Remove side heat shield of left ATL	Engine 177 in model 205	AR09.40-P-6026MNA
4	Relieve fuel pressure over diagnostic socket		AR07.03-P-1460-01MNA
		Pressure hose	Figure
5.1	Unclip electrical plug connections (1) on right crash plate (2)	Engine 177 in model 205
5.2	Unclip electrical lines (20) on right crash plate (2)	Engine 176 in model 463
6	Remove screw/bolts (3) and take off bracket for the vacuum line (4) on right crash plate (2)
7	Detach vacuum line from vacuum pump (4) and place to one side
8	Remove insulation (5)
9	Remove insulation (11)
10	Remove screw/bolts (6) and place crash plate (2) to one side
11	Detach fuel lines (7) at right high-pressure pump (8)	Thoroughly clean area around fuel lines (7, 8) at the locations to be separated. Failure can occur otherwise to the fuel system. Do not kink or bend the fuel lines (7, 8). Otherwise leaks will occur on the fuel lines (7, 8).
		Box wrench bit	Figure
12	Detach bracket of fuel lines (7, 8) at right cylinder head cover
13	Detach bracket of the fuel line (8) at right cylinder head cover
14	Detach fuel line (7) on right rail (18)	Thoroughly clean area around fuel line (7) on the locations to be separated. Failure can occur otherwise to the fuel system. Do not kink or bend the fuel lines (7). Otherwise the fuel line (7) can have leaks. Box wrench bit	Figure
15	Open mounting clamp (9) on fuel hose (10)
16	Pull fuel line (8) out of fuel hose (10)
17	Remove cable tie (21)	Engine 176 in model 463
18	Remove screw/bolt (24)	Engine 176 in model 463
19	Remove screws/bolts (23) and ventilation (25)	Engine 176 in model 463
20	Release and disconnect electrical connection of position sensor of the right intake camshaft	Engine 176 in model 463	AR15.12-P-2144MNF
21	Remove fuel lines (7, 8)	Do not kink or bend the fuel lines (7, 8). Otherwise leaks will occur on the fuel lines (7, 8).
22	Release and disconnect electrical connection (12)
23	Release and disconnect electrical connections (13)
24	Unclip bracket (14) on right rail (18)
25	Remove oil dipstick guide tube (15)	Engine 177 in model 205	AR18.40-P-3515MNA
26	Remove hold-down tool (16) between right rail (18) and fuel injectors (17)
27	Mark fuel injectors (17) relative to respective cylinder	If reusing the fuel injectors (17). Fuel injectors (17) must be inserted in the cylinder in which they were previously installed.
28	Remove screw/bolts (19) at right rail (18)	Unscrew screw/bolts (19) alternately each by half a revolution. Begin in the center of the right rail (18) and work outwards. Otherwise the right rail (18) may get damaged.
29	Detach right rail (18) from fuel injectors (17)
30	Remove all fuel injectors (17)	All fuel injectors (17) must be removed from the right cylinder head since the right rail (18) may only jointly be installed with the fuel injectors (17). Engine oil which comes out during disassembly of the right rail (18) or from the fuel injectors (17) is safe. The right rail (18) or the fuel injectors (17) can be re-used. In case of jammed fuel injectors (17). ↓ Remove fuel injectors (17).	AR07.03-P-0004-03MM
		Puller	Figure
	Clean
31	Clean fuel connections on fuel injectors (17)	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
	Check
32	Check fuel lines (7, 8) for damage and replace if necessary	Engine 176 in model 463	AR07.03-P-1010-03MM
		Engine 177 in model 205	AR07.03-P-1010-03MNA
		The sealing cone for the fuel lines (7, 8) must be checked before assembly. Leaks can occur otherwise. Assembly cleaner	*BR00.45-Z-1028-04A
	Install
33	Replace sealing packages for the fuel injectors (17) on right rail (18)		AR07.03-P-0004-02MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Drift	Figure
34	Replace sealing rings (26) and seals (27) on the fuel injectors (17)
35	Replace sealing rings (28) for fuel injectors (17)		AR07.03-P-0004-01MM
		The fuel injectors (17) must be installed immediately after calibration of the sealing rings (28) since the sealing rings (28) can swell due to the influence of air humidity. Otherwise the sealing rings (28) will be damaged during assembly. Assembly cleaner	*BR00.45-Z-1028-04A
		Assembly tool	Figure
36	Replace seal on overflow connector of the right rail (18)
37	Slide fuel injectors (17) marked during disassembly into right rail (18) and fasten in place using the hold-down tools (16)	If reusing the fuel injectors (17). Fuel injectors (17) must be inserted in the cylinder in which they were previously installed. Replace hold-down tool (16). Fuel injectors (17) may only be installed again in combination with the right rail (18) (as a unit).
38	Read off the injector quantity compensation (IMA) coding on fuel injectors (17) and take a note of it	When replacing fuel injectors (17).
39	Slide new fuel injectors (17) into right rail (18) and fasten in place using the hold-down tools (16)	When replacing fuel injectors (17). Replace hold-down tool (16). Fuel injectors (17) may only be installed again in combination with the right rail (18) (as a unit).
40	Slide rail (18) with fuel injectors (17) into the cylinder head
41	Screw screw/bolts (19) onto right rail (18)	Screw in screw/bolts (19) alternately each by half a revolution. Begin in the center of the right rail (18) and work outwards. Otherwise the right rail (18) may get damaged. Bolt, fuel distributor to cylinder head cover	*BA07.52-P-1001-01J
42	Install the oil dipstick guide tube (15)	Engine 177 in model 205	AR18.40-P-3515MNA
43	Clip in bracket (14) on right rail (18)
44	Plug in electrical connections (13) and lock into place
45	Plug in electrical connection (12) and lock into place
46	Position fuel lines (7, 8) in the installation position on engine	Do not kink or bend the fuel lines (7, 8). Otherwise leaks will occur on the fuel lines (7, 8).
47	Connect electrical connection of position sensor to the right intake camshaft and lock	Engine 176 in model 463	AR15.12-P-2144MNF
48	Screw in screw/bolts (24)	Engine 176 in model 463
49	Attach ventilation (25) and screw in screw/bolts (23)	Engine 176 in model 463
		Bolt, vent line to cylinder head cover/turbocharger	*BA01.20-P-1001-01J
50	Attach new cable tie (21)	Engine 176 in model 463
51	Break in fuel line (8) in fuel hose (10)
52	Mount mounting clamp (9) on fuel hose (10)	Replace mounting clamp (9). Pliers for click clamps	Figure
53	Detach fuel line (7) on right rail (18)		AR07.03-P-1010-02MNA
		Do not kink or bend fuel line (7). Otherwise the fuel line (7) can have leaks. Bolt, fuel line clamp to engine/bracket	*BA07.03-P-1004-01H
		Bolt, fuel line service connection to left cylinder head cover	*BA07.03-P-1002-01H
		Union nut, fuel line to fuel distributor/fuel system high-pressure pump	*BA07.03-P-1001-01H
		Box wrench bit	Figure
54	Mount bracket of the fuel line (8) at right cylinder head cover	Bolt, fuel line clamp to engine/bracket	*BA07.03-P-1004-01H
55	Detach bracket of fuel lines (7, 8) at right cylinder head cover	Bolt, fuel line clamp to engine/bracket	*BA07.03-P-1004-01H
56	Mount fuel lines (7, 8) on right high-pressure pump		AR07.03-P-1010-02MNA
		Do not kink or bend the fuel lines (7, 8). Otherwise leaks will occur on the fuel lines (7, 8). Bolt, fuel line clamp to engine/bracket	*BA07.03-P-1004-01H
		Bolt, fuel line service connection to left cylinder head cover	*BA07.03-P-1002-01H
		Union nut, fuel line to fuel distributor/fuel system high-pressure pump	*BA07.03-P-1001-01H
		Box wrench bit	Figure
57	Screw in screw/bolts (6) and fasten crash plate (2) of right high-pressure pump	Screw/bolt, shield plate to cylinder head	*BA07.02-P-1002-01E
58	Install insulation (11)
59	Install insulation (5)
60	Mount vacuum line (4) on the vacuum pump
61	Mount screw/bolts (3) on bracket of vacuum line on right crash plate (2)	Engine 176 in model 463 Screw/bolt, vacuum line bracket to lifting eye at the back of cylinder head	*BA43.05-P-1005-01B
		Engine 177 in model 205 Screw/bolt, bracket of vacuum line to shield plate of high-pressure pump	*BA43.05-P-1002-01O
62.1	Unclip electrical plug connections (1) on crash plate (2)	Engine 177 in model 205
62.2	Clip electrical lines (20) onto crash plate (2)	Engine 176 in model 463
63	Mount dust cap on service connection	Dust protection cap to service connection	*BA07.03-P-1005-01H
64	Install side heat shield of left ATL	Engine 177 in model 205	AR09.40-P-6026MNA
65	Install left and right air filter housing		AR09.10-P-1150MNA
66	Mount ground line on battery	Engine 176 in model 463	AR54.10-P-0003GW
		Engine 177 in model 205	AR54.10-P-0003LW
67	Read out fault memory using the diagnostic system and clear if necessary
		Engine 176 in model 463	AD00.00-P-2000-04A
		Engine 177 in model 205	AD00.00-P-2000-04B
68	Store injector quantity compensation (IMA) coding in ME-SFI [ME] control unit	When replacing fuel injectors (17).
		Engine 176 in model 463	AD00.00-P-2000-04A
		Engine 177 in model 205	AD00.00-P-2000-04B
	Check
69	Check fuel high-pressure circuit for leaktightness		AR07.03-P-1010-04MM
	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
70	Carry out an engine test run, checking the engine for proper operation and leaktightness

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

INJECTION PUMP, HIGH-PRESSURE FUEL PUMP

Number	Designation		Engine 176	Engine 177.980
BA07.02-P-1002-01E	Screw/bolt, shield plate to cylinder head	Nm	10	10

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation			Engine 176	Engine 177
BA07.03-P-1001-01H	Union nut, fuel line to fuel distributor/fuel system high-pressure pump	Stage 1	Nm	15	15
BA07.03-P-1001-01H		Stage 2	∠°	75 (+15)	75 (+15)

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 176	Engine 177
BA07.03-P-1002-01H	Bolt, fuel line service connection to left cylinder head cover	Nm	9	9

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 176	Engine 177
BA07.03-P-1004-01H	Bolt, fuel line clamp to engine/bracket	Nm	9	9

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 176	Engine 177
BA07.03-P-1005-01H	Dust protection cap to service connection	Nm	1	1

FUEL DISTRIBUTOR

Number	Designation		Engine 176	Engine 177.980
BA07.52-P-1001-01J	Bolt, fuel distributor to cylinder head cover	Nm	9	9

VACUUM PUMP

Number	Designation		Engine 177
BA43.05-P-1002-01O	Screw/bolt, bracket of vacuum line to shield plate of high-pressure pump	Nm	9

VACUUM PUMP

Number	Designation		Model 463
BA43.05-P-1005-01B	Screw/bolt, vacuum line bracket to lifting eye at the back of cylinder head	Nm	9

Fig 6: Identifying Drift (278 589 01 15 00)

Courtesy of MERCEDES-BENZ USA

Fig 7: Identifying Box Wrench Bit (000 589 80 03 00)

Courtesy of MERCEDES-BENZ USA

Fig 8: Identifying Pliers For Click Clamps (171 589 00 37 00)

Courtesy of MERCEDES-BENZ USA

Fig 9: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 10: Identifying Puller (278 589 00 33 00)

Courtesy of MERCEDES-BENZ USA

Fig 11: Identifying Assembly Tool (272 589 00 43 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

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