Remove/install rail

AR07.03-D-1010TSC

Remove/install rail

06.03.2020

Engine

274 in model 907

1

Electrical connector

2

Electrical connector

3

Electrical connector

4

Cable duct

5

Bolts

6

Electrical connectors

7

Electrical connector

8

Shielding

9

Electrical wiring harness

10

Electrical wiring harness

11

High pressure pipe

12

Rail

B4/21

Fuel pressure and temperature sensor

 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

 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

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 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

Remove ground line of the battery (G1).

AR54.10-D-0029TS

2

Remove cover of cylinder head cover.

AR01.20-D-5015TSC

3

Release and disconnect electrical connectors (1, 2, 3).

4

Remove screws (5).

5

Release and disconnect electrical connectors (6).

6

Lift cable duct (4) slightly and release and disconnect electrical connectors of the fuel injectors.

7

Release and disconnect electrical connector(7).

8

Remove electrical wiring harnesses (9, 10).

9

Swivel cable duct (4) out of the working area.

10

Remove screws of the shielding (8) in reverse order of the tightening procedure.

AR07.02-S-0815-01EG

11

Remove shielding (8).

12

Remove fuel pressure via the service connection.

AR07.03-S-1460-04EG

 Dust protection cap to service connection

*BA07.03-N-1001-01H

 Pressure hose

*119589046300

13

Remove high-pressure line (11) and seal connections with suitable stop plugs.

 Record plug

*129589009100

14

Remove screws of the rail (12) in reverse order of the tightening procedure.

AR07.03-S-1010-06EG

15

Mark fuel injectors relative to the respective cylinders.

16

Remove rail (12) from the fuel injectors and remove rail (12).

17

Remove fuel injectors.

AR07.03-S-0004-03EG

 Oil that comes out during removal of the rail (12) and fuel injectors is inconsequential. The rail (12) and fuel injectors can be re-used.

 All fuel injectors must be removed since the rail (12) may only be installed jointly with the fuel injectors.

 Puller

*278589003300

18

Change fuel pressure and temperature sensor (B4/21).

If a new rail (12) is installed.

AR07.04-D-0093TSC



Clean

19

Clean fuel connections on the fuel injectors.


During cleaning the fuel connections must be held downwards.
Dirt can get into the openings otherwise which would lead to failure of the fuel injectors.

Assembly cleaner

*BR00.45-Z-1028-04A



Install

20

Install new sealing packages of the fuel injectors on the rail (12).

AR07.03-S-0004-02EG

Assembly cleaner

*BR00.45-Z-1028-04A

 Drift

*278589011500

21

Install new sealing rings of the fuel injectors.

AR07.03-S-0004-01EG


Fuel injectors must be installed immediately after calibration of the sealing rings.
The sealing rings swell under the influence of the air humidity and can therefore be damaged during installation.

Assembly cleaner

*BR00.45-Z-1028-04A

 Assembly tool

*272589004300

22

Install fuel injectors in the rail (12).

 When reusing the fuel injectors they must be inserted into the cylinder in which it was previously installed.
Replace hold-down tools.

23

Install rail (12) with fuel injectors.

 The fuel injectors and rail (12) may only be installed as a unit.

24

Screw in screws of the rail (12) as per the tightening procedure.

AR07.03-S-1010-06EG

 Bolt, rail to cylinder head cover

*BA07.03-N-1004-01H

25

Install new high-pressure line (11).

AR07.03-S-1010-02EG

Topical note

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

AH00.00-P-0020-01A

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

AH00.00-P-0015-01CW


Do not kink or bend high-pressure line (11).
This prevents leaks or damage.

 Always install new high-pressure line (11).

 Union nut, high-pressure line to rail

*BA07.03-N-1002-01H

 Union nut, high-pressure line to high pressure pump

*BA07.03-N-1003-01H

 Tool kit

*000589109900

26

Install shielding (8).

27

Screw in screws of the shielding (8) as per the tightening procedure.

AR07.02-S-0815-01EG


Do not kink or bend high-pressure line (11).
This prevents leaks or damage.

 Bolt for high-pressure pump shielding

*BA07.02-N-1002-01F

28

Align cable duct (4) to the correct installation position.

29

Fasten electrical wiring harnesses (9, 10).

If the retaining clamps are damaged,



Replace retaining clips.

30

Connect electrical connector (7).

31

Lift cable duct (4) slightly and connect electrical connectors of the fuel injectors.

32

Establish the electrical connections (6).

33

Screw in screws (5).

 M6

*BA00.10-N-1002-01A

34

Connect electrical connectors (1, 2, 3).

35

Install cover of cylinder head cover.

AR01.20-D-5015TSC

36

Attach ground line of the battery (G1).

AR54.10-D-0029TS



Check

37

Check fuel high-pressure circuit.

AR07.03-S-1010-04EG

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-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

38

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

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 High pressure pump

Number

Designation

Engine 274 in model 907

BA07.02-N-1002-01F

Bolt for high-pressure pump shielding

Nm

20

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274 in model 907

BA07.03-N-1001-01H

Dust protection cap to service connection

Plastic

Nm

2

Metal

Nm

15

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274 in model 907

BA07.03-N-1002-01H

Union nut, high-pressure line to rail

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274 in model 907

BA07.03-N-1003-01H

Union nut, high-pressure line to high pressure pump

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274 in model 907

BA07.03-N-1004-01H

Bolt, rail to cylinder head cover

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01