Remove/install left rail

AR07.03-P-1011MNB

Remove/install left rail

06.03.2020

Engine

178 in model 190

1

Bolts

2

Strut

3

Purge line

4

Ventilation

5

Electrical connectors

7

Bolts

8

Engine wiring harness

10

Bolts

11

Left rail

12

Electrical connector

16

Hold-down tool

17

Fuel injectors

 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

 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

General information on work on gasoline direct injection system

AH07.00-P-2000-01A



Remove

1

Detach ground line from battery

AR54.10-P-0003RG

2

Remove screws (1) and remove strut (2)

3

Remove left fuel system high pressure pump

AR07.02-P-1023MNB

4

Unclip purge line (3) at ventilation (4)

5

Disconnect electrical connections (5)

6

Disconnect electrical connection (12)

7

Unclip electrical connection for oxygen sensor on bracket of the left cylinder head cover

8

Remove screw/bolts (7) and detach fuel distributor at left cylinder head cover

9

Detach engine wiring harness (8) on left cylinder head cover

10

Remove hold-down tool (16) between left rail (11) and fuel injectors (17) of left cylinder bank

11

Mark fuel injectors (17) of left cylinder bank relative to the respective cylinder

 When reusing the fuel injectors (17) they must be inserted into the cylinder in which they were previously installed.

12

Screw in screw/bolts (10) on left rail (11)


Remove screw/bolts (10) alternately each by half a revolution. Begin in the center of the left rail (11) and work outwards.
Otherwise damage can occur to the left rail (11).

13

Detach left rail (11) from fuel injectors(17)

14

Remove fuel injectors (17) on left cylinder bank

 Engine oil which comes out during disassembly of the rail (11) or from the fuel injectors (17) is safe. The left rail (11) or the fuel injectors (17) can be re-used.

 All fuel injectors (17) must be removed since the left rail (11) may only be installed together with the fuel injectors (17).

 Puller

*278589003300

In case of firmly attached fuel injectors (17)



Remove injection nozzles

AR07.03-P-0004-03MM



Clean

15

Clean fuel connections on fuel injectors(17)


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



Install

16

Replace sealing packages for the fuel injectors (17) on left rail (11)

AR07.03-P-0004-02MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Drift

*278589011500

17

Replace sealing rings and seals on the fuel injectors (17)

AR07.03-P-0004-01MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Assembly tool

*272589004300

18

Replace seal on overflow connector of the left rail (11)

19

Slide fuel injectors (17) into left rail (11) and fasten in place using the hold-down tools (16)

 When reusing the fuel injectors (17) they must be inserted into the cylinder in which they were previously installed.

 Fuel injectors (17) may only be installed again in combination with the rail (11) (as a unit).

 Replace hold-down tool (16).

20

Slide left rail (11) with fuel injectors (17) into the cylinder head

21

Screw in screw/bolts (10) on left rail (11)


Screw in screw/bolts (10) alternately each by half a revolution. Begin in the center of the left rail (11) and work outwards.
Otherwise damage can occur to the left rail (11).

 Bolt, fuel distributor to cylinder head cover

*BA07.52-P-1001-01J

22

Mount engine wiring harness (8) on left cylinder head cover

 Bolt, engine wiring harness to cylinder head cover

*BA15.18-P-1001-01G

23

Screw in screw/bolts (7) and mount fuel distributor on the left cylinder head cover

 Bolt, fuel line connection piece to left cylinder head cover

*BA07.03-P-1003-01H

24

Clip electrical connection for oxygen sensor into bracket of the left cylinder head cover

25

Attach electrical connector (12)

26

Plug in electrical connectors (5)

27

Clip purge line (3) onto ventilation (4)

28

Install left fuel system high pressure pump

AR07.02-P-1023MNB

29

Insert strut (2) and tighten screw/bolts (1)

 Bolt, retaining plate to body

*BA62.30-P-1002-01I

 Bolt, strut to body/retaining plate

*BA62.30-P-1001-01I

30

Mount ground line on battery

AR54.10-P-0003RG



Check

31

Check fuel high-pressure circuit for leaktightness.

AR07.03-P-1010-04MM

32

Read out fault memory using the diagnostic system and clear if necessary



AD00.00-P-2000-04B

 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

33

Carry out an engine test run, checking the engine for proper operation and leaktightness

 Injection nozzles, injection valves, lines

Number

Designation

Engine 178

BA07.03-P-1003-01H

Bolt, fuel line connection piece to left cylinder head cover

Nm

9

 Fuel distributor

Number

Designation

Engine 178

BA07.52-P-1001-01J

Bolt, fuel distributor to cylinder head cover

Nm

9

 Engine wiring harness

Number

Designation

Engine 178

BA15.18-P-1001-01G

Bolt, engine wiring harness to cylinder head cover

Nm

9

 Cross member and front reinforcement

Number

Designation

Model 190

BA62.30-P-1001-01I

Bolt, strut to body/retaining plate

M8

Nm

30

 Cross member and front reinforcement

Number

Designation

Model 190

BA62.30-P-1002-01I

Bolt, retaining plate to body

M8

Nm

30

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01