Remove/Install Rail - Ar07.03-D-1010TSC

Engine 274 in model 907

	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
	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
	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
	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
	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	Fig 5
13	Remove high-pressure line (11) and seal connections with suitable stop plugs.	Record plug	Fig 2
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	Fig 4
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	Fig 6
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	Fig 3
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
	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	Fig 1
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
	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
	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
BA00.10-N-1002-01A	M6	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
BA00.10-N-1002-01A	M6	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
BA07.03-N-1001-01H	Dust protection cap to service connection	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	A°	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	S°	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

Fig 1: Tool Kit (000 589 10 99 00)

Fig 2: Record Plug (129 589 00 91 00)

Fig 3: Assembly Tool (272 589 00 43 00)

Fig 4: Puller (278 589 00 33 00)

Fig 5: Pressure Hose (119 589 04 63 00)

Fig 6: Drift (278 589 01 15 00)

REPAIR MATERIALS

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