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Remove/install left rail - AR07.03-P-1011MNA

ENGINE 176 in MODEL 463 

ENGINE 177 in MODEL 205 

MODIFICATION NOTES

20.05.2016 Union nut, fuel line to fuel distributor/fuel system high pressure pump   BA07.03-P-1001-01H
13.06.2016 General information for replacement of the fuel hose (13), added Operation step 55  

Shown on ENGINE 177 

Fig 1: Left Rail Remove/Install Components - Shown On Engine 177 (1 Of 4)
G11138975Courtesy of MERCEDES-BENZ USA
Fig 2: Left Rail Remove/Install Components - Shown On Engine 177 (2 Of 4)
G11138976Courtesy of MERCEDES-BENZ USA
Fig 3: Left Rail Remove/Install Components - Shown On Engine 177 (3 Of 4)
G11138977Courtesy of MERCEDES-BENZ USA
Fig 4: Left Rail Remove/Install Components - Shown On Engine 177 (4 Of 4)
G11138978Courtesy of MERCEDES-BENZ USA
DANGER 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
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 Note on calculation of tightening torque when using insertion or socket tools with various effective lengths   AH00.00-P-0015-01CW
IMPORTANT General information on work on gasoline direct injection system   AH07.00-P-2000-01A
REMOVING 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
2.1 Remove left and right air filter housing Engine 177 in model 205 AR09.10-P-1150MNA
2.2 Remove left-hand air filter housing Engine 176 in model 463 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 (1)   AR07.03-P-1460-01MNA
    TORQUE SPECIFICATION Dust protection cap to service connection *BA07.03-P-1005-01 
    SPECIAL TOOL Pressure hose Figure
5 Unclip electrical line (3) on fuel line (4)    
6 Remove the ignition coil (5) Engine 177 in model 205 AR15.12-P-2003MNA
7 Detach fuel feed (6) at diagnostic socket (1) and place to one side    
8 Remove screw/bolts (26) and remove diagnostic socket (1) from left cylinder head cover    
9 Remove insulation (7)    
10 Detach fuel lines (4, 10) at left high-pressure pump NOTES Thoroughly clean area around fuel lines (4, 10) at the locations to be separated.
Failure can occur otherwise to the fuel system.
NOTES Do not kink or bend the fuel lines (4, 10).
Otherwise leaks will occur on the fuel lines (4, 10).		  
SPECIAL TOOL Box wrench bit Figure
11 Detach bracket of fuel lines (4, 10) at left cylinder head cover    
12 Detach bracket of the fuel line (10) at left cylinder head cover    
13 Remove filler neck (11)    
14 Open mounting clamp (12) on fuel hose (13) SPECIAL TOOL Pliers for click clamps Fig 7
15 Detach fuel line (10) from fuel hose (13) NOTES Thoroughly clean area around fuel line (10) on the locations to be separated.
Failure can occur otherwise to the fuel system.
NOTES Do not kink or bend the fuel lines (10).
Otherwise the fuel line (10) can suffer leaks.		  
16 Remove insulation (14)    
17 Detach fuel line (4) on left rail (15) NOTES Thoroughly clean area around fuel line (4) on the locations to be separated.
Failure can occur otherwise to the fuel system.
NOTES Do not kink or bend fuel line (4).
Otherwise the fuel line (4) can have leaks.
SPECIAL TOOL Box wrench bit		 Figure
18 Unclip engine wiring harness (16) at left cylinder head cover    
19 Release and disconnect electrical connections (17)    
20 Release and disconnect electrical connection (18)    
21 Unclip wiring harness (27) on left cylinder head cover and ventilation (21)    
22 Remove screw/bolt (19) and remove ground line at left cylinder head cover    
23 Unclip vacuum line (20) at ventilation (21)    
24 Remove screws/bolts (22) and ventilation (21)    
25 Remove fuel line (10) NOTES Do not kink or bend fuel line (10).
Otherwise the fuel line (10) can have leaks.		  
26 Remove hold-down tool (23) between left rail (15) and fuel injectors (24) of the left cylinder bank    
27 Mark fuel injectors (24) of left cylinder bank relative to the respective cylinder When reusing the fuel injectors (24) of the left cylinder bank.
IMPORTANT Fuel injectors (24) of the left cylinder bank must be inserted in the cylinder in which they were previously installed.		  
28 Push terminal block at the sidewall on the left upwards Engine 177 in model 205  
29 Remove screw/bolts (25) NOTES Remove screw/bolts (25) alternately each by half a revolution. Begin in the center of the left rail (15) and work outwards.
Otherwise the left rail (15) may get damaged.		  
30 Detach left rail (15) from fuel injectors (24) of left cylinder bank    
31 Remove all fuel injectors (24) of the left cylinder bank IMPORTANT All fuel injectors (24) of the left cylinder bank must be removed, since the left rail (15) may only be installed together with the fuel injectors (24) of left cylinder bank.
IMPORTANT Engine oil which comes out during disassembly of the left rail (15) or from the fuel injectors (24) of the left cylinder bank is safe. The left rail (15) or the fuel injectors (24) of the left cylinder bank can be re-used.
in the case of jammed fuel injectors (24) of the left cylinder bank
↓
Remove fuel injectors (24) of the left cylinder bank		 AR07.03-P-0004-03MM
    SPECIAL TOOL Puller Figure
CLEAN Clean     
32 Clean fuel connections on fuel injectors (24)   AR07.03-P-1010-04MM
    NOTES 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 
INSPECT Check     
33 Check fuel lines (4, 10) for damage and replace if necessary Engine 176 in model 463 AR07.03-P-1010-03MM
    Engine 177 in model 205
NOTES The sealing cone for the fuel lines (4, 10) must be checked before assembly.
Otherwise leaks will occur on the fuel lines (4, 10).		 AR07.03-P-1010-03MNA
    Assembly cleaner *BR00.45-Z-1028-04A 
INSTALLING Install     
34 Replace sealing packages for the fuel injectors (24) of the left cylinder bank on left rail (15)   AR07.03-P-0004-02MM
    Assembly cleaner *BR00.45-Z-1028-04A 
    SPECIAL TOOL Drift Figure
35 Replace sealing rings (29) and seals (30) on the fuel injectors (24) of the left cylinder bank    
36 Replace sealing rings (31) on fuel injectors (24) of the left cylinder bank NOTES The fuel injectors (24) of the cylinder bank must be installed immediately after calibration of the sealing rings (31) since the sealing rings (31) due to the influence of air humidity.
Otherwise the sealing rings (31) will be damaged during assembly.		 AR07.03-P-0004-01MM
    Assembly cleaner *BR00.45-Z-1028-04A 
SPECIAL TOOL Assembly tool Figure
37 Replace seal on overflow connector of the left rail (15)    
38 Insert the fuel injectors (24) of the left cylinder bank marked during removal in the left rail (15) and fasten with hold-down tools (23) When reusing the fuel injectors (24) of the left cylinder bank.
IMPORTANT Fuel injectors (24) of the left cylinder bank must be placed in the cylinder they were installed in before.
IMPORTANT Replace hold-down tool (23).
IMPORTANT Fuel injectors (24) of the left cylinder bank may only be installed again in combination with the left rail (15) (as a unit).		  
39 Read off the injector quantity compensation (IMA) coding on fuel injectors (24) of left cylinder bank and take a note of it For replacing the fuel injectors (24) of the left cylinder bank.  
40 Push new fuel injectors (24) of the left cylinder bank in the left rail (15) and fasten with hold-down tools (23) For replacing the fuel injectors (24) of the left cylinder bank.
IMPORTANT Replace hold-down tool (23).
IMPORTANT Fuel injectors (24) of the left cylinder bank may only be installed again in combination with the left rail (15) (as a unit).		  
41 Insert left rail (15) with fuel injectors (24) of the left cylinder bank in left cylinder head    
42 Screw in screw/bolts (25) NOTES Screw in screw/bolts (25) alternately each by half a revolution. Begin in the center of the left rail (15) and work outwards.
Otherwise the left rail (15) may get damaged.
TORQUE SPECIFICATION Bolt, fuel distributor to cylinder head cover		 *BA07.52-P-1001-01J 
43 Push terminal block at the left sidewall downwards into the original position Engine 177 in model 205  
44 Position fuel line (10) in the installation position on engine NOTES Do not kink or bend fuel line (10).
The fuel line (10) can be damaged otherwise.		  
45 Attach ventilation (21) and tighten screw/bolts (22) TORQUE SPECIFICATION Bolt, vent line to cylinder head cover/turbocharger *BA01.20-P-1001-01J 
46 Unclip vacuum line (20) at ventilation (21)    
47 Mount ground line at left cylinder head cover and tighten screw/bolt (19) TORQUE SPECIFICATION Bolt, engine wiring harness ground to cylinder head cover *BA15.10-P-1003-05F 
48 Unclip wiring harness (27) on left cylinder head cover and ventilation (21)    
49 Plug in electrical connection (18) and lock into place    
50 Place electrical connections (17) and lock    
51 Clip in engine wiring harness (16) at left cylinder head cover    
52 Mount fuel line (4) on left rail (15)   AR07.03-P-1010-02MNA
    NOTES Do not kink or bend fuel line (4).
The fuel line (4) can be damaged otherwise.
TORQUE SPECIFICATION Bolt, fuel line clamp to engine/bracket		 *BA07.03-P-1004-01H 
    TORQUE SPECIFICATION Bolt, fuel line service connection to left cylinder head cover *BA07.03-P-1002-01H 
    TORQUE SPECIFICATION Union nut, fuel line to fuel distributor/fuel system high-pressure pump *BA07.03-P-1001-01H 
    SPECIAL TOOL Box wrench bit Figure
53 Install insulation (14)    
54 Break in fuel line (10) in fuel hose (13) NOTES Do not kink or bend fuel line (10).
The fuel line (10) can be damaged otherwise.		  
55 Close mounting clamp (12) on fuel hose (13) IMPORTANT Replace mounting clamp (12) and fuel hose (13).
SPECIAL TOOL Pliers for click clamps		 Fig 7
56 Install filler neck (11) IMPORTANT Replace sealing ring.
TORQUE SPECIFICATION Bolt, filler neck to cylinder head cover		 *BA01.20-P-1006-01J 
57 Mount bracket of the fuel line (10) on left cylinder head cover TORQUE SPECIFICATION Bolt, fuel line clamp to engine/bracket *BA07.03-P-1004-01H 
58 Mount bracket of fuel lines (4, 10) at left cylinder head cover TORQUE SPECIFICATION Bolt, fuel line clamp to engine/bracket *BA07.03-P-1004-01H 
59 Mount fuel lines holder (4, 10) on left high-pressure pump   AR07.03-P-1010-02MNA
    NOTES Do not kink or bend the fuel lines (4, 10).
The fuel lines (4, 10) may get damaged otherwise.
TORQUE SPECIFICATION Union nut, fuel line to fuel distributor/fuel system high-pressure pump		 *BA07.03-P-1001-01H 
    Box wrench bit Figure
60 Install insulation (7)    
61 Mount diagnostic socket (1) onto left cylinder head cover and tighten screw/bolts (26) TORQUE SPECIFICATION Bolt, fuel line service connection to left cylinder head cover *BA07.03-P-1002-01H 
62 Mount fuel feed (6) at diagnostic socket (1) TORQUE SPECIFICATION Union nut, fuel hose to diagnostic socket/fuel line *BA07.03-P-1006-01H 
63 Install ignition coil (5) Engine 177 in model 205 AR15.12-P-2003MNA
64 Clip electrical line (3) into fuel line (4)    
65 Screw dust cap onto diagnostic socket (1) TORQUE SPECIFICATION Dust protection cap to service connection *BA07.03-P-1005-01H 
66 Install side heat shield of left ATL Engine 177 in model 205 AR09.40-P-6026MNA
67.1 Install left and right air filter housing Engine 177 in model 205 AR09.10-P-1150MNA
67.2 Install left-hand air filter housing Engine 176 in model 463
Engine 177 in model 205		 AR09.10-P-1150MNA
68 Mount ground line on battery Engine 176 in model 463 AR54.10-P-0003GW
    Engine 177 in model 205 AR54.10-P-0003LW
69 Read out fault memory using the diagnostic system and clear if necessary    
REFER TO SELF-DIAGNOSTIC SYSTEMS   Engine 176 in model 463 AD00.00-P-2000-04A
REFER TO SELF-DIAGNOSTIC SYSTEMS   Engine 177 in model 205 AD00.00-P-2000-04B
70 Store injector quantity compensation (IMA) coding in ME-SFI [ME] control unit When replacing fuel injectors (24).  
REFER TO SELF-DIAGNOSTIC SYSTEMS   Engine 176 in model 463 AD00.00-P-2000-04A
REFER TO SELF-DIAGNOSTIC SYSTEMS   Engine 177 in model 205 AD00.00-P-2000-04B
INSPECT Check     
71 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
72 Carry out an engine test run, checking the engine for proper operation and leaktightness    
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER

Number Designation Engine 176 Engine 177
BA01.20-P-1001-01J Bolt, vent line to cylinder head cover/turbocharger Nm 9 9
CRANKCASE VENTILATION SYSTEM, CYLINDER HEAD COVER

Number Designation Engine 176 Engine 177
BA01.20-P-1006-01J Bolt, filler neck to cylinder head cover Nm 9 9
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
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
INJECTION NOZZLES, INJECTION VALVES, LINES

Number Designation Engine 176 Engine 177
BA07.03-P-1006-01H Union nut, fuel hose to diagnostic socket/fuel line Nm 24 24
FUEL DISTRIBUTOR

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

Number Designation Engine 176 Engine 177
BA15.10-P-1003-05F Bolt, engine wiring harness ground to cylinder head cover Nm 9 9
Fig 5: Identifying Drift (278 589 01 15 00)
G11138979Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Box Wrench Bit (000 589 80 03 00)
G11138980Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Pliers For Click Clamps (171 589 00 37 00)
G11138981Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Pressure Hose (119 589 04 63 00)
G11138982Courtesy of MERCEDES-BENZ USA
Fig 9: Identifying Puller (278 589 00 33 00)
G11138983Courtesy of MERCEDES-BENZ USA
Fig 10: Identifying Assembly Tool (272 589 00 43 00)
G11138984Courtesy 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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