Remove/install right rail

AR07.03-P-1012MNA

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

P07.03-2353-06

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

P07.03-2355-06

16	Hold-down tool
17	Fuel injectors

P07.03-2356-06

Shown on engine 176

20	Electrical line
21	Cable tie
22	Ignition coil
23	Bolts
24	Screw
25	Ventilation

P07.03-2367-06

17	Fuel injector
26	Sealing ring
27	Seal
28	Sealing ring

P07.03-2378-03

 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

272 589 00 43 00

Assembly tool

171 589 00 37 00

Pliers for click clamps

000 589 80 03 00

Box wrench bit

278 589 00 33 00

Puller

119 589 04 63 00

Pressure hose

278 589 01 15 00

Drift

Repair materials

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	A 000 986 56 01

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