Remove/install rail - AR07.03-P-1010MT

ENGINE 133 in MODEL 117, 156, 176

ENGINE 270 in MODEL 117, 156, 176, 242, 246.2

MODIFICATION NOTES

12.12.13	Union nut, fuel line to fuel distributor	ENGINE 133.980	BA07.03-P-1001-01F
12.12.13	Union nut, fuel line to high-pressure pump	ENGINE 133.980	BA07.03-P-1002-01F
6.5.14	Tightening procedure for rail (1) inserted	Operation step 24, 35

Shown on model 246.242

Fig 1: Rail Remove/Install Components - Shown On Model 246.242 (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Rail Remove/Install Components - Shown On Model 246.242 (2 Of 2)

Courtesy of MERCEDES-BENZ USA

	Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.	No parts of the body or limbs should be within the operating range of the mechanism when moving components.	AS00.00-Z-0009-01A
	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 contact with 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-0003NKB
	Notes on battery		AH54.10-P-0001-01A
2	Remove upper engine cover
3	Empty low-temperature circuit	Engine 133 in model 117, 156, 176
3	Empty low-temperature circuit	Engine 133 in model 117, 156, 176	AR20.00-P-1144MTA
4	Remove screw/bolts (5) and expose return line (6), detach at the connecting points (6T) and remove	Engine 133 in model 117, 156, 176
4		Engine 133 in model 117, 156, 176	AR09.41-P-1311-01AL
5	Remove low-temperature circuit expansion reservoir (7) with holder	Engine 133 in model 117, 156, 176
5		Engine 133 in model 117, 156, 176	AR20.30-P-4951MTA
6	Remove Intake camshaft valve lift actuator	Engine 270 in model 117, 156, 176, 246.2 with code A14 (Camtronic)
6	Remove Intake camshaft valve lift actuator		AR05.20-P-6500MT
7	Remove insulation on high-pressure pump (4)
8	Disconnect purge line (11) at charge air cooler and expose	Engine 133 in model 117, 156, 176
9	Detach electrical connection (10) from purging pressure sensor, expose and set aside	Engine 133 in model 117, 156, 176
10	Detach holder (8) for wide open throttle vent line from air intake pipe (9) and place to one side with attached purge lines (11)	Engine 133 in model 117, 156, 176 Do not bend the purge lines (11) and vent lines too strongly. These can break otherwise and must be replaced.
11	Detach vacuum line (12) from ATL aneroid capsule, expose and set aside	Engine 133 in model 117, 156, 176
12	Detach vacuum line (13) from vacuum pump, expose and set aside	Engine 133 in model 117, 156, 176
13	Detach oxygen sensor connector holder (14) from the cylinder head cover; to do this unclip coolant line and oxygen sensor connector and remove screw/bolts	Engine 133 in model 117, 156, 176
14	Remove screw/bolt for oil dipstick guide tube holder (15) on cylinder head cover	Engine 133 in model 117, 156, 176 The oil dipstick guide tube remains in the oil pan.
15.1	Remove screw/bolts 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
15.2	Detach engine wiring harness at cylinder head cover and place to one side	Engine 133 in model 117, 156, 176
			AR01.00-P-2410-02MTA
		Secure engine wiring harness outside the working area with cable ties. See operation steps to remove the cylinder head cover.
16	Relieve fuel pressure in fuel high-pressure circuit		AR07.03-P-1460-02MM
17	Remove high-pressure line (3) between rail (1) and high-pressure pump (4)	Do not kink or bend high-pressure line (3). Leaks or damage can occur otherwise.
18	Remove air intake pipe completely	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. Therefore the oil separator, the vent lines and the air intake pipe must be replaced after disconnection of the connection.
19	Detach partial and wide open throttle 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)
19			AR09.10-P-8131MT
20	Unclip vacuum lines for the 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
		See "Remove/install air intake pipe".
21	Clip in engine wiring harness onto air intake pipe and cylinder head cover	Engine 270 in model 117, 156, 176, 242, 246.2 except code 494 (US version)
21			AR09.10-P-8131MT
22	Disconnect electrical connection at fuel pressure and temperature sensor	Engine 270 in model 117, 156, 176, 242, 246.2
23	Disconnect electrical connection at quantity control valve	Engine 270 in model 117, 156, 176, 242, 246.2
24	Remove screws/bolts (1s) opposite to the tightening procedure		AR07.03-P-1010-06MR
25	Remove hold-down tool (2) between rail (1) and fuel injectors (Y76)
26	Mark fuel injectors relative to the respective cylinder	When reusing the fuel injectors, they must be inserted into the cylinder in which it was previously installed.
27	Detach rail (1) from fuel injectors (Y76)
28	Remove fuel injectors (Y76)		AR07.03-P-0004MT
		All fuel injectors must be pulled out since the rail (2) may only jointly be installed with the fuel injectors. In case of jammed fuel injectors: ↓ Remove fuel injectors.
			AR07.03-P-0004-03MM
		Puller	Figure
29	Remove spark plugs	Engine 270 in model 242 with code 924 (Bivalent natural gas drive)
			AP15.10-P-1580NK
	Clean
30	Clean fuel connections on fuel injectors (Y76)	During cleaning the fuel connections must be held downwards. Dirt can enter the openings otherwise.
31	Clean bores of the injector tip in cylinder head from combustion residues and suction off combustion residues	Engine 270 in model 242 with code 924 (Bivalent natural gas drive) Clean bores of the injector tip in cylinder head with cylinder brush. The seals will otherwise be damaged on the fuel injectors (Y76) upon installation. Always maintain rotational speed and cleaning time. Stock removal on the cylinder head can otherwise occur and therefore to damage which can lead to exchange of the cylinder head. Insert cylinder brush into cordless screwdriver and clean with a rotational speed +<500/min per bore for about 4 s. At the same time the cleaning residue must be suctioned off during a cleaning process over the spark plug bore. After cleaning the injector well must be blown out with compressed air whereby the suction must be maintained by the spark plug bore. Remove connection hose from adapter, connect to vacuum cleaner and introduce connection hose in the spark plug bore. Subsequently suction off cleaning residue over the spark plug bore.
		Adapter	Figure
		Cylinder brush	Figure
	Check
32	Check high-pressure line and replace if necessary		AR07.03-P-1010-03MM
		The sealing cone for high-pressure lines must be checked before assembly. Do this to avoid leaks and damage.
		Assembly cleaner	*BR00.45-Z-1028-04A
	Install
33	Replace sealing packages for the fuel injectors (Y76) on rail (1)		AR07.03-P-0004-02MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Drift	Fig 5
34	Replace sealing rings and seal at fuel injectors (Y76)		AR07.03-P-0004-01MM
		Fuel injectors (Y76) 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 assembly.
		Assembly cleaner	*BR00.45-Z-1028-04A
		Assembly tool	Figure
35	Put fuel injectors (Y76) into rail (1) and fasten in place using the hold-down tools (2)	When reusing the fuel injectors they must be inserted into the cylinder in which it was previously installed. Fuel injectors may only be installed again in combination with the rail (as a whole) (1). Replace hold-down tool (2).
36	Mount rail (1) with fuel injectors (Y76)
37	Screw in screw/bolts (1s) of the rail (1) according to the tightening procedure		AR07.03-P-1010-06MR
37		Screw/bolt, fuel distributor to cylinder head cover	*BA07.52-P-1001-01H
38	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
39	Connect electrical connections to fuel injectors (Y76)	Engine 270 in model 117, 156, 176, 242, 246.2
40	Connect electrical connection to quantity control valve	Engine 270 in model 117, 156, 176, 242, 246.2
41	Connect electrical connection at fuel pressure and temperature sensor	Engine 270 in model 117, 156, 176, 242, 246.2
42	Clip in engine wiring harness onto air intake pipe and cylinder head cover	Engine 270 in model 117, 156, 176, 242, 246.2 except code 494 (US version)
42			AR09.10-P-8131MT
43	Clip in vacuum line for the purge line (11) onto engine wiring harness and filler neck for the engine oil	Engine 270 in model 117, 156, 176, 242, 246.2 except code 494 (US version)
		See "Remove/install air intake pipe".
			AR09.10-P-8131MT
44	Mount the partial and wide open throttle vent lines at the air intake pipe	Engine 270 in model 117, 156, 176, 242, 246.2 except code 494 (US version)
44			AR09.10-P-8131MT
45	Install air intake pipe	Engine 270 in model 117, 156 with code 494 (US version)
45	Install air intake pipe	Engine 270 in model 117, 156 with code 494 (US version)	AR09.10-P-8131MTU
46.1	Mount the engine wiring harness and bracket at cylinder head cover	Engine 270 in model 117, 156, 176, 242, 246.2
46.2	Mount engine wiring harness at cylinder head cover and check for correct routing	Engine 133 in model 117, 156, 176
46.2		Engine 133 in model 117, 156, 176	AR01.00-P-2410-02MTA
47	Mount oxygen sensor connector holder (14) on cylinder head cover and clip in coolant line and oxygen sensor connector in the holder	Engine 133 in model 117, 156, 176
48	Mount oil dipstick guide tube on the cylinder head cover	Engine 133 in model 117, 156, 176
48	Mount oil dipstick guide tube on the cylinder head cover	Bolt, guide tube to cylinder head cover	*BA01.45-P-1003-01V
49	Mount vacuum line (13) on the vacuum pump	Clip in vacuum line (13) on the holder for the filler neck for engine oil and ensure correct installation of lines.
50	Mount vacuum line (12) on the ATL aneroid capsule	The vacuum line (12) must not be clipped into the holder for the filler neck for engine oil. Ensure that routing of lines is correct.
51	Mount holder (8) for wide open throttle bleed line on air intake pipe (9)	Engine 133 in model 117, 156, 176 Install new sealing rings.
52	Mount electrical connection (10) on purging pressure sensor	Engine 133 in model 117, 156, 176
53	Mount purge line (11) on charge air cooler	Engine 133 in model 117, 156, 176 Ensure that routing of lines is correct.
54	Insert insulation on high-pressure pump (4)
55	Install lift actuator valve	Engine 270 in model 117, 156, 176, 246.2 with code A14 (Camtronic)
55	Install lift actuator valve		AR05.20-P-6500MT
56	Install low-temperature circuit expansion reservoir (7) with holder	Engine 133 in model 117, 156, 176
57	Install return line (6)	Engine 133 in model 117, 156, 176
58	Fill and bleed low-temperature circuit	Engine 133 in model 117, 156, 176
58	Fill and bleed low-temperature circuit	Engine 133 in model 117, 156, 176	AR20.00-P-1144MTA
59	Install upper engine cover
60	Attach ground line to battery		AR54.10-P-0003NKB
61	Read out fault memory using the diagnostic system and clear if necessary
			AD00.00-P-2000-04A
	Check
62	Check fuel high-pressure circuit for leaktightness		AR07.03-P-1010-04MM
	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
63	Carry out an engine test run, checking the engine for proper operation and leaktightness

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

Fig 3: Cylinder Brush (270 589 01 68 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Adapter (270 589 00 68 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Drift (278 589 01 15 00)

Courtesy of MERCEDES-BENZ USA

Fig 6: Puller (278 589 00 33 00)

Courtesy of MERCEDES-BENZ USA

Fig 7: Assembly Tool (272 589 00 43 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1028-04A	Assembly cleaner	Adolf Wurth GmbH & Co. KG