Remove/install fuel rail - AR07.03-P-1010RKB

ENGINE 157, 278 in MODEL 231 

Shown on model 231.473 

Fig 1: Fuel Rail Remove/Install Components - Shown On Model 231.473

Courtesy of MERCEDES-BENZ USA

	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
	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 battery ground line		AR54.10-P-0003RK
	Notes on battery		AH54.10-P-0001-01A
2	Remove upper engine covers
3	Remove air filter housing
4	Remove insulation on rail (1)	If installed
5	Remove ME-SFI [ME] control unit (N3/10)		AR07.08-P-7008RKB
6	Disconnect electrical connection at fuel pressure and temperature sensor	Only when removing the right rail (1)
7	Remove engine wiring harness from rail (1) and fuel injectors (Y76)		AR01.00-P-2410-02RKB
8	Relieve fuel pressure over diagnostic socket		AR07.03-P-1460-01VA
		Protective cap on service valve	*BA07.03-P-1007-01E
		Pressure hose	Figure
9	Relieve fuel pressure in fuel system high-pressure circuit		AR07.03-P-1460-02MM
10	Remove high-pressure lines from high-pressure pump to rail (1)	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 left and right rail (1)	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)	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	When reusing the fuel injectors they (Y76) 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) from the cylinder head	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. When reusing the fuel injectors they (Y76) must be inserted into the cylinder in which it was previously installed. Fuel injectors (Y76) must be pulled out since the rail (1) may only jointly be installed with the fuel injectors (Y76). In case of jammed fuel injectors (Y76): ↓	AR07.03-P-0004RKB
		Remove injection nozzle.	AR07.03-P-0004-03MM
		Puller	Figure
	Clean
17	Clean fuel connections on fuel injectors (Y76)	During cleaning the fuel connections must be held downwards. This prevents dirt getting into the openings.
	Check
18	Check high-pressure line and replace if necessary		AR07.03-P-1010-03MM
		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
	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	Figure
20	Replace sealing rings for the fuel injectors (Y76).		AR07.03-P-0004-01MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Assembly tool	Figure
21	Insert 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 (as a whole) (1). Replace hold-down tool (3).
22	Replace seal (2) on spilling of the rail (1)
23	Insert 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	Install high-pressure lines	Do not kink or bend high-pressure lines. This prevents leaks and damage.	AR07.03-P-1010-02MMB
		Union nut, fuel line to fuel distributor	*BA07.03-P-1001-01E
		Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01E
		Bolt, fuel line service valve to cylinder head cover	*BA07.03-P-1003-01E
		Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head	*BA07.03-P-1004-01E
		Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase	*BA07.03-P-1005-01E
		Bolt, fuel line clamp to charge air distribution line	*BA07.03-P-1006-01E
26	Mount engine wiring harness from rail (1) and fuel injectors (Y76)		AR01.00-P-2410-02RKB
27	Connect electrical connection at fuel pressure and temperature sensor	Only when installing the right rail (1)
28	Install ME-SFI [ME] control unit (N3/10)		AR07.08-P-7008RKB
29	Install insulation on rail (1)	Only if insulation was removed
30	Install air filter housing
31	Install upper engine covers
32	Mount ground line on battery		AR54.10-P-0003RK
	Notes on battery		AH54.10-P-0001-01A
33	Read out fault memory using the diagnostic system and clear if necessary
			AD00.00-P-2000-04A
	Check
34	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
35	Carry out an engine test run, checking the engine for proper operation and leaktightness

Fig 2: Identifying Drift (278 589 01 15 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Puller (278 589 00 33 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Assembly Tool (272 589 00 43 00)

Courtesy of MERCEDES-BENZ USA