LEMON Manuals: Even more car manuals for everyone
Home >> Mercedes Benz >> 2017 >> GLE550e >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Mixture Formation - 166 Chassis - 4 Of 7 >> Testing & Repair >> Remove/Install Rail >> Remove/Install Rail - AR07.03-P-1010MLJ

Remove/Install Rail - AR07.03-P-1010MLJ

ENGINE 157, 278 in MODEL 166 

ENGINE 157, 278 in MODEL 292 

MODIFICATION NOTES

04.07.2016 Union nut, fuel line to fuel distributor   BA07.03-P-1001-01E
04.07.2016 Union nut, fuel line to high-pressure pump   BA07.03-P-1002-01E

Shown on model 166.074 

G11975031Courtesy of MERCEDES-BENZ USA

Shown on model 166.074 

G11975032Courtesy of MERCEDES-BENZ USA
  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
  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-0003GZ
  Notes on battery   AH54.10-P-0001-01A
2 Remove upper engine covers    
3 Remove air filter housing    
4 Remove insulation on left or right rail (1)    
5 Remove ME-SFI [ME] control unit   AR07.08-P-7008MLJ 
6 Remove engine compartment partition wall on the left and right    
7 Disconnect electrical connection at fuel pressure and temperature sensor When removing the right rail (1)  
8 Detach engine wiring harness from left or right from rail (1) and fuel injectors (Y76)   AR01.00-P-2410-02MLJ
9 Disconnect vacuum line (4) on vacuum pump When removing the left rail (1)  
10 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
11 Relieve fuel pressure in fuel high-pressure circuit   AR07.03-P-1460-02MM 
12 Remove high-pressure lines from high-pressure pumps on 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).		  
13 Remove high-pressure line between left and right rail (1) NOTES
Do not kink or bend high-pressure lines. Leaks and damage can occur otherwise for possible reuse (after successfully passing checking) of the high-pressure line.		  
14 Remove screws/bolts (1s) NOTES
Remove screw/bolts (1s) for removal of the left or right rail (1) alternately by respectively turning half a revolution from the center outwards.
Damage to the left or right 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 the fuel injectors (Y76) were previously installed.  
17 Detach rail (1) from fuel injectors (Y76)    
18 Remove fuel injectors (Y76) from the cylinder head IMPORTANT Engine oil which comes out during disassembly of the left or right rail (1) or from the fuel injectors (Y76) is safe. The respective rail (1) or the fuel injectors (Y76) can be re-used.
IMPORTANT Fuel injectors (Y76) must be removed since the respective rail (1) may only jointly be installed with the fuel injectors (Y76).
In case of jammed fuel injectors (Y76):
↓
Remove injection nozzle.		 AR07.03-P-0004-03MM 
    SPECIAL TOOL Puller Fig 3
CLEAN 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.		  
INSPECT Check     
20 Check high-pressure line for leaktightness and replace if necessary NOTES
The sealing cone for high-pressure lines must be checked before assembly.
Do this to avoid leaks and damage.		 AR07.03-P-1010-03MM 
    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 1
22 Replace seal (2) on spilling of the rail (1)    
23 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 respective the rail (1) (as a whole).
IMPORTANT Replace hold-down tool (3).		  
24 Insert respective rail (1) with fuel injectors (Y76) in cylinder head    
25 Screw in screw/bolts (1s) NOTES
Screw in screw/bolts (1s) for installation of the respective rail (1) alternately by respectively turning half a revolution from the center outwards.
Damage to the rail (1) can occur otherwise.
TORQUE SPECIFICATION Screw/bolt, fuel distributor to cylinder head cover		 *BA07.52-P-1001-01G 
26 Mount high-pressure line on respective rail (1) and high-pressure pump NOTES
Do not kink or bend high-pressure lines.
Otherwise leaks and damage may occur.
IMPORTANT The work instructions absolutely must be observed for assembly work.		 AR07.03-P-1010-02MMB 
    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 
27 Mount engine wiring harness from respective rail (1) and fuel injectors (Y76)    
28 Connect electrical connection at fuel pressure and temperature sensor When installing right rail (1)  
29 Install engine compartment partition wall on the left and right    
30 Install ME-SFI [ME] control unit   AR07.08-P-7008MLJ 
31 Remove insulation on left or right rail (1)    
32 Install air filter housing    
33 Install upper engine covers    
34 Mount ground line on battery   AR54.10-P-0003GZ
  Notes on battery   AH54.10-P-0001-01A
35 Read out fault memory using the diagnostic system and clear if necessary    
REFER TO SELF-DIAGNOSTIC SYSTEMS     AD00.00-P-2000-04A
INSPECT Check     
36 Check fuel high-pressure circuit for leaktightness   AR07.03-P-1010-04MM 
WARNING 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 buttoned-up and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
37 Perform an engine test run; in doing so check 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 In case of reusability Nm 22 22
For new lines Stage 1 Nm 15 15
Stage 2 ∠° 90 90
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 157 Engine 278
BA07.03-P-1002-01E Union nut, fuel line to high-pressure pump In case of reusability Nm 22 22
For new lines Stage 1 Nm 15 15
Stage 2 ∠° 90 90
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 1: Identifying Drift (278 589 01 15 00)
G10247781Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Pressure Hose (119 589 04 63 00)
G12078803Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Puller (278 589 00 33 00)
G10107849Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner Adolf Wurth GmbH & Co. KG
scientia non olet · About LEMON Manuals