Remove/install rail

AR07.03-P-1010MT

Remove/install rail

06.03.2020

Engine

133 in model 117, 156, 176

Engine

270 in model 117, 156, 176, 242, 246.2

Modification notes

20.11.2019

Document completely revised.

Shown on model 246.242

1

Rail

1s

Screw

2

Hold-down tool

3

High pressure pipe

4

High pressure pump

Y76

Fuel injectors

Shown on model 246.242

5

Bolts

6

Return flow pipe

6T

Return line connecting points

7

Low-temperature circuit expansion reservoir

8

Bracket

9

Air intake pipe

10

Electrical connector

11

Purge line

12

Vacuum line (for aneroid capsule)

13

Vacuum line (for vacuum pump)

14

Oxygen sensor connector holder

15

Oil dipstick tube bracket screw

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-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 contactwith 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

 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 closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

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

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A



Remove

1

Remove ground line from battery.

AR54.10-P-0003NKB

Topical note

Notes on battery

AH54.10-P-0001-01A

2

Remove upper engine cover.

Engine 133 in model 117, 156, 176
Engine 270 in model 117, 156, 176, 242, 246.2



Engine 133 in model 117, 156, 176

AP01.10-P-2405-01A

3

Drain low-temperature circuit.

Engine 133 in model 117, 156, 176

AR20.00-P-1144MTA

4

Remove bolts (5) and expose return line (6).

Engine 133 in model 117, 156, 176

5

Disconnect return line (6) at separating points (6T) and remove.

Engine 133 in model 117, 156, 176

AR09.41-P-1311-01AL

6

Remove low-temperature circuit expansion reservoir (7) with bracket.

Engine 133 in model 117, 156, 176

AR20.30-P-4951MTA

7

Remove valve lift changeover actuator.

Engine 270 in model 117, 156, 176, 246.2
with code A14 (Camtronic)

AR05.20-P-6500MT

8

Remove insulation at high-pressure pump (4).

9

Disconnect purge line (11) at charge air cooler and expose.

Engine 133 in model 117, 156, 176

10

Release and disconnect electrical connector (10) from purging pressure sensor, expose and place to one side.

Engine 133 in model 117, 156, 176

11

Remove bracket (8) of wide open throttle bleed line from air intake pipe (9) and place to one side with connected purge lines (11).

Engine 133 in model 117, 156, 176


Do not bend purge lines (11) and bleed line too much.
These can break otherwise and must be replaced.

12

Remove vacuum line (12) from exhaust gas turbocharger diaphragm capsule, expose and set aside.

Engine 133 in model 117, 156, 176

13

Remove vacuum line (13) from vacuum pump, expose and place to one side.

Engine 133 in model 117, 156, 176

14

Remove lambda sensor connector holder (14) from cylinder head cover.

Engine 133 in model 117, 156, 176

15

Remove oil dipstick tube bracket screw (15) at cylinder head cover.

Engine 133 in model 117, 156, 176

 Oil dipstick tube remains in oil pan.

16.1

Remove screws from engine wiring harness at cylinder head cover and place engine wiring harness to one side.

Engine 270 in model 117, 156, 176, 242, 246.2


Do not kink lines, do not subject lines to tension.
Otherwise damage will occur.

16.2

Remove engine wiring harness at cylinder head cover and place to one side.

Engine 133 in model 117, 156, 176

AR01.00-P-2410-02MTA


Do not kink lines, do not subject lines to tension.
Otherwise damage will occur.

17

Release fuel pressure in the fuel high-pressure circuit.

AR07.03-P-1460-02MM

18

Remove high-pressure line (3) between rail (1) and high-pressure pump (4) and seal openings with suitable stop plugs.


Do not kink or bend high-pressure line (3).
Leaks or damage can occur otherwise.

 Box wrench bit

*000589690300

 Record plug

*129589009100

19

Fully remove air intake pipe.

Engine 270 in model 117, 156
with code 494 (US version)

AR09.10-P-8131MTU

 The vent lines, the oil separator and the air intake pipe are firmly connected together. For this reason, the oil separator, bleed lines and air intake pipe are replaced after the disconnection of the connection.

20

Remove partial and full load vent line at air intake pipe and place to one side.

Engine 270 in model 117, 156, 176, 242, 246.2
except code 494 (US version)

AR09.10-P-8131MT

21

Unclip vacuum lines of purge line (11) at engine wiring harness and filler neck for engine oil and place to one side.

Engine 270 in model 117, 156, 176, 242, 246.2
except code 494 (US version)

AR09.10-P-8131MT

22

Unclip engine wiring harness at air intake pipe and cylinder head cover.

Engine 270 in model 117, 156, 176, 242, 246.2
except code 494 (US version)

AR09.10-P-8131MT

23

Release and disconnect electrical connector at fuel pressure and temperature sensor.

Engine 270 in model 117, 156, 176, 242, 246.2

24

Release and disconnect electrical connector at quantity control valve.

Engine 270 in model 117, 156, 176, 242, 246.2

25

Release and disconnect electrical connectors of fuel injectors (Y76).

Engine 270 in model 117, 156, 176, 242, 246.2

26

Remove screws (1s) in reverse order to tightening procedure.

AR07.03-P-1010-06MR

27

Remove hold-down tools (2) between rail (1) and fuel injectors (Y76).

28

Mark fuel injectors relative to corresponding cylinder.

 Where fuel injectors (Y76) are reused, insert these in cylinder in which they were previously installed.

29

Remove rail (1) from fuel injectors (Y76).

30

Remove fuel injectors (Y76) and seal injector well bores with suitable stop plugs.

AR07.03-P-0004MT

 Remove all fuel injectors (Y76), rail (1) may only be installed together with fuel injectors (Y76).

If fuel injectors (Y76) are stuck,



Remove fuel injectors (Y76).

AR07.03-P-0004-03MM

 Plug

*270589039100

 Puller

*278589003300



Clean

31

Clean fuel connections at fuel injectors (Y76).


Hold fuel connections downwards during cleaning.
Otherwise, dirt will get into openings and result in failure of fuel injectors (Y76).

Assembly cleaner

*BR00.45-Z-1028-04A



Check

32

Check fuel injectors (Y76) for damage.

If there are problems,



Replace fuel injectors (Y76).

33

Check high-pressure line (3) and replace if necessary.

AR07.03-P-1010-03MM


Check sealing cones of high-pressure line (3) before assembly.
Do this to avoid leaks and damage.

Assembly cleaner

*BR00.45-Z-1028-04A



Install

34

Replace sealing packages of fuel injectors (Y76) at rail (1).

AR07.03-P-0004-02MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Drift

*278589011500

35

Replace sealing rings and seals at fuel injectors (Y76).

If fuel injectors (Y76) are to be reused.

AR07.03-P-0004-01MM


Immediately install fuel injectors (Y76) after attachment of sealing rings.
The sealing rings swell under the influence of the air humidity and can therefore be damaged during assembly.

Assembly cleaner

*BR00.45-Z-1028-04A

 Assembly tool

*272589004300

36

Insert fuel injectors (Y76) in rail (1) and secure with hold-down tools (2).

 When replacing fuel injectors (Y76), immediately install these after removal of transport protective caps. Leaks can occur otherwise.

 Ensure rail (1) is correctly seated relative to fuel injectors (Y76). Sealing packages of fuel injectors (Y76) will otherwise be damaged.

 Where fuel injectors (Y76) are reused, place these in cylinder in which they were previously installed.

 Only install fuel injectors (Y76) together with rail (1).

 Replace hold-down tools (2).

37

Remove stop plugs of injector well bores.

 Plug

*270589039100

38

Install rail (1) with fuel injectors (Y76).

39

Screw in screws (1s) of rail (1) according to tightening procedure.

AR07.03-P-1010-06MR

 Screw/bolt, fuel distributor to cylinder head cover

*BA07.52-P-1001-01H

40

Install high-pressure line (3) between rail (1) and high-pressure pump (4).

AR07.03-P-1010-02MT


Do not kink or bend high-pressure line (3).
Leaks or damage can occur otherwise.

 Union nut, fuel line to fuel distributor

*BA07.03-P-1001-01F

 Union nut, fuel line to high-pressure pump

*BA07.03-P-1002-01F

 Box wrench bit

*000589690300

41

Connect and lock electrical connectors of fuel injectors (Y76).

Engine 270 in model 117, 156, 176, 242, 246.2

42

Connect and lock electrical connector at quantity control valve.

Engine 270 in model 117, 156, 176, 242, 246.2

43

Connect and lock electrical connector at fuel pressure and temperature sensor.

Engine 270 in model 117, 156, 176, 242, 246.2

44

Clip engine wiring harness into air intake pipe and cylinder head cover.

Engine 270 in model 117, 156, 176, 242, 246.2
except code 494 (US version)

AR09.10-P-8131MT

45

Clip vacuum lines of purge line (11) into engine wiring harness and filler neck for engine oil.

Engine 270 in model 117, 156, 176, 242, 246.2
except code 494 (US version)

AR09.10-P-8131MT

46

Attach partial and full load vent line to air intake pipe.

Engine 270 in model 117, 156, 176, 242, 246.2
except code 494 (US version)

AR09.10-P-8131MT

47

Install air intake pipe.

Engine 270 in model 117, 156
with code 494 (US version)

AR09.10-P-8131MTU

48.1

Attach engine wiring harness to cylinder head cover.

Engine 270 in model 117, 156, 176, 242, 246.2

48.2

Attach engine wiring harness to cylinder head cover and check for correct routing.

Engine 133 in model 117, 156, 176

AR01.00-P-2410-02MTA

49

Attach lambda sensor connector holder (14) to cylinder head cover and clip coolant line and lambda sensor connector into holder.

Engine 133 in model 117, 156, 176

50

Attach oil dipstick tube to cylinder head cover.

Engine 133 in model 117, 156, 176

 Bolt, guide tube to cylinder head cover

*BA01.45-P-1003-01V

51

Attach vacuum line (13) to vacuum pump.

 Clip in vacuum line (13) on the holder for the filler neck for engine oil and ensure correct installation of lines.

52

Attach vacuum line (12) to exhaust gas turbocharger diaphragm capsule.

 Do not clip vacuum line (12) into bracket at filler neck for engine oil. Ensure that routing of lines is correct.

53

Attach bracket (8) of full load vent line to air intake pipe (9).

Engine 133 in model 117, 156, 176

 Install new sealing rings.

54

Attach electrical connector (10) to purging pressure sensor.

Engine 133 in model 117, 156, 176

55

Attach purge line (11) to charge air cooler.

Engine 133 in model 117, 156, 176

 Ensure that routing of lines is correct.

56

Install insulation at high-pressure pump (4).

57

Install valve lift adjustment actuator.

Engine 270 in model 117, 156, 176, 246.2
with code A14 (Camtronic)

AR05.20-P-6500MT

58

Install low-temperature circuit expansion reservoir (7) with bracket.

Engine 133 in model 117, 156, 176

59

Install, connect and lock return line (6).

Engine 133 in model 117, 156, 176

AR09.41-P-1311-01AL

60

Fill and vent low-temperature circuit.

Engine 133 in model 117, 156, 176

AR20.00-P-1144MTA

61

Install ground line at battery.

AR54.10-P-0003NKB

Topical note

Notes on battery

AH54.10-P-0001-01A

62

Read out fault memory with vehicle diagnosis system and delete if necessary.



AD00.00-P-2000-04A

63

Store injector quantity compensation coding in motor control module (MCM).

For installation of new fuel injectors (Y76).



AD00.00-P-2000-04A



Check

64

Check fuel high-pressure circuit for leak tightness.

AR07.03-P-1010-04MM



AD00.00-P-2000-04A

65

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

66

Install upper engine cover.

Engine 133 in model 117, 156, 176
Engine 270 in model 117, 156, 176, 242, 246.2



Engine 133 in model 117, 156, 176

AP01.10-P-2405-01A

 Oil pan

Number

Designation

Engine 133.980

BA01.45-P-1003-01V

Bolt, guide tube to cylinder head cover

Nm

9

 Injection nozzles, injection valves, lines

Number

Designation

Engine 133.980

Engine 270

BA07.03-P-1001-01F

Union nut, fuel line to fuel distributor

Stage 1

Nm

15

15

Stage 2

°

90

75

Stage 3

°

–

25

 Injection nozzles, injection valves, lines

Number

Designation

Engine 133.980

Engine 270

BA07.03-P-1002-01F

Union nut, fuel line to high-pressure pump

Stage 1

Nm

15

15

Stage 2

°

90

75

Stage 3

°

–

25

 Fuel distributor

Number

Designation

Engine 133.980

Engine 270

BA07.52-P-1001-01H

Screw/bolt, fuel distributor to cylinder head cover

Nm

9

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01