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

ENGINE 276.8 in MODEL 217, 222

Shown on model 222.067

Fig 1: Rail Remove/Install Components - Shown On Model 222.067

Courtesy 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
	Remove
1	Detach ground line from battery		AR54.10-P-0003LF
2	Remove air filter housing on the left or right	When removing the left or right rail (1).	AR09.10-P-1150LFA
3	Remove crash plate and insulation on the high-pressure pump	When removing the left or right rail (1).	AR07.02-P-1020LFA
4	Relieve fuel pressure over diagnostic socket		AR07.03-P-1460-01VA
		Cap on service connection	*BA07.03-P-1007-01D
		Pressure hose	Figure
5	Relieve fuel pressure in fuel system high-pressure circuit		AR07.03-P-1460-02MM
6	Unclip vacuum line at soundproofing on the rail	Engine 276.8 in model 222.163 When removing left rail (1).
7	Remove soundproofing over rail
8	Detach high-pressure line on rail (1) and high-pressure pump
9	Detach low-pressure line at high-pressure pump
10	Detach engine wiring harness on the rail (1)		AR01.00-P-2410-02LFA
11	Detach electrical connection on fuel pressure and temperature sensor		AR07.04-P-0050LFA
12	Remove screw/bolts (1s)	When removing left rail (1). 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.
13	Remove hold-down device (3) between rail (1) and fuel injectors (Y76)
14	Mark fuel injectors (Y76) relative to the respective cylinder	When reusing the fuel injectors (Y76) they must be inserted into the cylinder in which the fuel injectors (Y76) were previously installed.
15	Detach rail (1) from fuel injectors (Y76)
16	Remove fuel injectors (Y76)	Engine 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. All fuel injectors (Y76) must be removed since the rail (1) may only jointly be installed with the fuel injectors (Y76).	AR07.03-P-0004LFA
		In case of jammed fuel injectors (Y76) ↓ Remove injection nozzles	AR07.03-P-0004-03MM
		SI Puller	Figure
	Clean
18	Check high-pressure line for damage and replace if necessary		AR07.03-P-1010-03MM
		Assembly cleaner The sealing cone for high-pressure lines must be checked before assembly ↓ Otherwise leaks and damage may occur	*BR00.45-Z-1028-04A
	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
		Drift	Fig 2
20	Replace sealing rings and seal at fuel injectors (Y76)		AR07.03-P-0004-01MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Assembly tool	Figure
21	Replace seal (2) on spilling of the rail (1)
22	Slide fuel injectors (Y76) into rail (1) and fasten in place using the hold-down tools (3)	When reusing the fuel injectors they (Y76) must be inserted into the cylinder in which it was previously installed. Fuel injectors (Y76) may only be installed again in combination with the rail (1) (as a unit). Replace Hold-down tool (3).
23	Slide rail (1) with fuel injectors (Y76) into the cylinder head
24	Screw in screw/bolts (1s)	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. Screw/bolt, fuel distributor to cylinder head cover	*BA07.52-P-1001-01G
25	Connect electrical connection to fuel pressure and temperature sensor (B4/25)	When installing left rail (1).
26	Mount engine wiring harness from rail (1) and fuel injectors (Y76)		AR01.00-P-2410-02LFA
27	Mount low-pressure line at high-pressure pump	Do not kink or bend low-pressure lines. Otherwise leaks and damage may occur. Union nut, fuel line to fuel distributor	*BA07.03-P-1001-01D
28	Mount high-pressure line on rail (1) and high-pressure pump		AR07.03-P-1010-02MMA
		Do not kink or bend high-pressure lines. Otherwise leaks and damage may occur. The work instructions absolutely must be observed for assembly work. Union nut, fuel line to fuel distributor	*BA07.03-P-1001-01D
		Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01D
		Screw/bolt, fuel line service connection to cylinder head cover	*BA07.03-P-1003-01D
		Screw/bolt, fuel line clamps	*BA07.03-P-1005-01D
		Union nut, fuel line to service connection	*BA07.03-P-1008-01D
29	Remove soundproofing over rail		AR07.02-P-1020LFA
30	Unclip vacuum line at soundproofing on the rail	Engine 276.8 in model 222.163 When removing left rail (1).
31	Install crash plate and insulation on the high-pressure pump	When installing the left or right rail (1).	AR07.02-P-1020LFA
32	Install air filter housing on the left or right	When installing the left or right rail (1).	AR09.10-P-1150LFA
33	Mount ground line on battery		AR54.10-P-0003LF
34	Read out fault memory with diagnostic system		AD00.00-P-2000-04B
	Check
35	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
36	Carry out an engine test run, checking the engine for proper operation and leaktightness