Remove/install right rail

AR07.03-P-1012MNA

Remove/install right rail

06.03.2020

Engine

176 in model 463

up to model year 2019

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

25.08.2016

Screw/bolt, shield plate to cylinder head

Engine 176

BA07.02-P-1002-01E

25.08.2016

Screw/bolt, shield plate to cylinder head

Engine 177.980

BA07.02-P-1002-01E

30.01.2017

Union nut, fuel line to fuel distributor/fuel system high pressure pump

BA07.03-P-1001-01H

Shown on ENGINE 177

1

Plug connections

5

Insulation

6

Bolts

11

Insulation

15

Guide tube for oil dipstick

Shown on ENGINE 177

2

Crash plate

3

Bolts

4

Vacuum line

6

Bolts

7

Fuel line

8

Fuel line

9

Mounting clamp

10

Fuel hose

12

Electrical connector

13

Electrical connectors

14

Bracket

18

Right rail

19

Bolts

16

Hold-down tool

17

Fuel injectors

Shown on engine 176

20

Electrical line

21

Cable tie

22

Ignition coil

23

Bolts

24

Screw

25

Ventilation

17

Fuel injector

26

Sealing ring

27

Seal

28

Sealing ring

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

General information on work on gasoline direct injection system

AH07.00-P-2000-01A



Remove

1

Detach ground line from battery

Engine 176 in model 463
up to model year 2019
Engine 177 in model 205

Engine 176 in model 463 (except 463.234)
as of model year 2013 up to model year 2019

AR54.10-P-0003GW

Engine 177 in model 205

AR54.10-P-0003LW

2

Remove left and right air filter housing

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

AR07.03-P-1460-01MNA

 Pressure hose

*119589046300

5.1

Unclip electrical plug connections (1) on right crash plate (2)

Engine 177 in model 205

5.2

Unclip electrical lines (20) on right crash plate (2)

Engine 176 in model 463
up to model year 2019

6

Remove screw/bolts (3) and take off bracket for the vacuum line (4) on right crash plate (2)

7

Detach vacuum line from vacuum pump (4) and place to one side

8

Remove insulation (5)

9

Remove insulation (11)

10

Remove screw/bolts (6) and place crash plate (2) to one side

11

Detach fuel lines (7) at right high-pressure pump (8)


Thoroughly clean area around fuel lines (7, 8) at locations to be separated.
Failure can occur otherwise to the fuel system.


Do not kink or bend fuel lines (7, 8).
Leaks may otherwise occur in the fuel lines (7, 8).

 Box wrench bit

*000589800300

12

Detach bracket of the fuel lines (7, 8) from the right cylinder head cover

13

Detach bracket of the fuel line (8) at right cylinder head cover

14

Detach fuel line (7) on right rail (18)


Thoroughly clean area around fuel line (7) at locations to be separated.
Failure can occur otherwise to the fuel system.


Do not kink or bend the fuel lines (7).
Leaks may otherwise occur in the fuel line (7).

 Box wrench bit

*000589800300

15

Open mounting clamp (9) on the fuel hose (10)

16

Pull fuel line (8) out of fuel hose (10)

17

Remove cable tie (21)

Engine 176 in model 463
up to model year 2019

18

Remove bolt (24)

Engine 176 in model 463
up to model year 2019

19

Remove screws/bolts (23) and ventilation (25)

Engine 176 in model 463
up to model year 2019

20

Release and disconnect electrical connection of position sensor of the right intake camshaft

Engine 176 in model 463
up to model year 2019

AR15.12-P-2144MNF

21

Remove fuel lines (7, 8)


Do not kink or bend fuel lines (7, 8).
Leaks may otherwise occur in the fuel lines (7, 8).

22

Release and disconnect electrical connector (12)

23

Release and disconnect electrical connectors (13)

24

Unclip bracket (14) on right rail (18)

25

Remove oil dipstick guide tube (15)

Engine 177 in model 205

AR18.40-P-3515MNA

26

Remove hold-down tool (16) between right rail (18) and fuel injectors (17)

27

Mark fuel injectors (17) relative to respective cylinder

If reusing the fuel injectors (17).

 Fuel injectors (17) must be inserted in the cylinder in which they were previously installed.

28

Remove screws (19) from the right rail (18)


Unscrew screw/bolts (19) alternately each by half a revolution. Begin in center of right rail (18) and work outwards.
Otherwise the right rail (18) may get damaged.

29

Detach right rail (18) from fuel injectors (17)

30

Remove all fuel injectors (17)

 All fuel injectors (17) must be removed from the right cylinder head since the right rail (18) may only jointly be installed with the fuel injectors (17).

 Engine oil that leaks out during disassembly of the right rail (18) or the fuel injectors (17) is safe. The right rail (18) and fuel injectors (17) can be re-used.

In case of jammed fuel injectors (17).



Remove fuel injectors (17).

AR07.03-P-0004-03MM

 Puller

*278589003300



Clean

31

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



Check

32

Check fuel lines (7, 8) for damage and replace if necessary

Engine 176 in model 463
up to model year 2019

AR07.03-P-1010-03MM

Engine 177 in model 205

AR07.03-P-1010-03MNA


The sealing cones for fuel lines (7, 8) must be checked before assembly.
Leaks can occur otherwise.

Assembly cleaner

*BR00.45-Z-1028-04A



Install

33

Install new sealing packages of the fuel injectors (17) on the right rail (18)

AR07.03-P-0004-02MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Drift

*278589011500

34

Replace sealing rings (26) and seals (27) on the fuel injectors (17)

35

Replace sealing rings (28) for fuel injectors (17)

AR07.03-P-0004-01MM


The fuel injectors (17) must be installed immediately after calibration of the sealing rings (28) since the sealing rings (28) can swell due to the influence of air humidity.
Otherwise the sealing rings (28) will be damaged during assembly.

Assembly cleaner

*BR00.45-Z-1028-04A

 Assembly tool

*272589004300

36

Install new seal on the overflow connector of the right rail (18)

37

Slide fuel injectors (17) marked during disassembly into right rail (18) and fasten in place using the hold-down tools (16)

If reusing the fuel injectors (17).

 Fuel injectors (17) must be inserted in the cylinder in which they were previously installed.

 Replace hold-down tool (16).

 Fuel injectors (17) may only be installed again in combination with the right rail (18) (as a unit).

38

Read off the injector quantity compensation (IMA) coding on fuel injectors (17) and take a note of it

If installing new fuel injectors (17).

39

Slide new fuel injectors (17) into right rail (18) and fasten in place using the hold-down tools (16)

If installing new fuel injectors (17).

 Replace hold-down tool (16).

 Fuel injectors (17) may only be installed again in combination with the right rail (18) (as a unit).

40

Slide rail (18) with fuel injectors (17) into the cylinder head

41

Screw screw/bolts (19) onto right rail (18)


Screw in screws/bolts (19) alternately turning each by half a revolution. Begin in center of right rail (18) and work outwards.
Otherwise the right rail (18) may get damaged.

 Bolt, fuel distributor to cylinder head cover

*BA07.52-P-1001-01J

42

Install oil dipstick guide tube (15)

Engine 177 in model 205

AR18.40-P-3515MNA

43

Clip in bracket (14) on right rail (18)

44

Plug in electrical connections (13) and lock into place

45

Plug in electrical connector (12) and lock into place

46

Position fuel lines (7, 8) in the installation position on engine


Do not kink or bend fuel lines (7, 8).
Leaks may otherwise occur in the fuel lines (7, 8).

47

Connect electrical connection of position sensor to the right intake camshaft and lock

Engine 176 in model 463
up to model year 2019

AR15.12-P-2144MNF

48

Screw in screw/bolt (24)

Engine 176 in model 463
up to model year 2019

49

Attach ventilation (25) and screw in screw/bolts (23)

Engine 176 in model 463
up to model year 2019

 Bolt, vent line to cylinder head cover/turbocharger

*BA01.20-P-1001-01J

50

Attach new cable tie (21)

Engine 176 in model 463
up to model year 2019

51

Break in fuel line (8) in fuel hose (10)

52

Mount mounting clamp (9) on fuel hose (10)

 Replace mounting clamp (9).

 Pliers for click clamps

*171589003700

53

Detach fuel line (7) on right rail (18)

AR07.03-P-1010-02MNA


Do not kink or bend fuel line (7).
Leaks may otherwise occur in the fuel line (7).

 Bolt, fuel line clamp to engine/bracket

*BA07.03-P-1004-01H

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

*BA07.03-P-1002-01H

 Union nut, fuel line to fuel distributor/fuel system high-pressure pump

*BA07.03-P-1001-01H

 Box wrench bit

*000589800300

54

Mount bracket of the fuel line (8) at right cylinder head cover

 Bolt, fuel line clamp to engine/bracket

*BA07.03-P-1004-01H

55

Detach bracket of fuel lines (7, 8) at right cylinder head cover

 Bolt, fuel line clamp to engine/bracket

*BA07.03-P-1004-01H

56

Mount fuel lines (7, 8) on right high-pressure pump

AR07.03-P-1010-02MNA


Do not kink or bend fuel lines (7, 8).
Leaks may otherwise occur in the fuel lines (7, 8).

 Bolt, fuel line clamp to engine/bracket

*BA07.03-P-1004-01H

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

*BA07.03-P-1002-01H

 Union nut, fuel line to fuel distributor/fuel system high-pressure pump

*BA07.03-P-1001-01H

 Box wrench bit

*000589800300

57

Screw in screw/bolts (6) and fasten crash plate (2) of right high-pressure pump

 Bolt, shield to cylinder head/cylinder head cover

*BA07.02-P-1002-01E

58

Install insulation (11)

59

Install insulation (5)

60

Mount vacuum line (4) on vacuum pump

61

Mount screw/bolts (3) on bracket of vacuum line on right crash plate (2)

 Engine 176 in model 463
up to model year 2019Screw/bolt, vacuum line bracket to lifting eye at the back of cylinder head

*BA43.05-P-1005-01B

 Engine 177 in model 205Screw/bolt, bracket of vacuum line to shield plate of high-pressure pump

*BA43.05-P-1002-01O

62.1

Unclip electrical plug connections (1) on crash plate (2)

Engine 177 in model 205

62.2

Clip electrical lines (20) onto crash plate (2)

Engine 176 in model 463
up to model year 2019

63

Mount dust cap on service connection

 Dust protection cap to service connection

*BA07.03-P-1005-01H

64

Install side heat shield of left ATL

Engine 177 in model 205

AR09.40-P-6026MNA

65

Install left and right air filter housing

AR09.10-P-1150MNA

66

Mount ground line on battery

Engine 176 in model 463
up to model year 2019
Engine 177 in model 205

Engine 176 in model 463 (except 463.234)
as of model year 2013 up to model year 2019

AR54.10-P-0003GW

Engine 177 in model 205

AR54.10-P-0003LW

67

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



Engine 176 in model 463
up to model year 2019

AD00.00-P-2000-04A



Engine 177 in model 205

AD00.00-P-2000-04B

68

Store injector quantity compensation (IMA) coding in ME-SFI [ME] control unit

If installing new fuel injectors (17).



Engine 176 in model 463
up to model year 2019

AD00.00-P-2000-04A



Engine 177 in model 205

AD00.00-P-2000-04B



Check

69

Check fuel high-pressure circuit for leaktightness.

AR07.03-P-1010-04MM

 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

70

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

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 176

BA01.20-P-1001-01J

Bolt, vent line to cylinder head cover/turbocharger

Nm

9

 Injection pump, high-pressure fuel pump

Number

Designation

Engine 176

Engine 177

BA07.02-P-1002-01E

Bolt, shield to cylinder head/cylinder head cover

Nm

10

10

 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

In case of reusability

Nm

22

22

For new lines

Stage 1

Nm

15

15

Stage 2

°

90

90

 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

 Fuel distributor

Number

Designation

Engine 176

Engine 177

BA07.52-P-1001-01J

Bolt, fuel distributor to cylinder head cover

Nm

9

9

 Vacuum pump

Number

Designation

Engine 177

BA43.05-P-1002-01O

Screw/bolt, bracket of vacuum line to shield plate of high-pressure pump

Nm

9

 Vacuum pump

Number

Designation

Model 463
up to model year 2019

BA43.05-P-1005-01B

Screw/bolt, vacuum line bracket to lifting eye at the back of cylinder head

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01