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Remove fuel distributor with injection valves - AR07.03-P-1450Q

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ENGINE 271.940 in MODEL 203.042 /242 /742, 209.342 /442 

ENGINE 271.946 in MODEL 203.046 /246 /746 

ENGINE 271.948 in MODEL 203.040 /240 /740 

ENGINE 271.921 in MODEL 203.730 

ENGINE 271.955 in MODEL 209.341 /441 

Fig 1: Identifying Air Filter Housing, Fuel Feed Line, Fuel Distributor, Service Valve, Electrical Connectors And Fuel Injectors
G04737000
MODIFICATION NOTES

16.5.06 "Disconnect/connect battery ground line" removed    
REMOVING Removing     
DANGER Risk of explosion  caused by fuel igniting, risk of poisoning  caused by inhaling and swallowing fuel and risk of injury  to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A
1 Pull engine cover upwards off the cylinder head cover    
2 Remove air filter housing (1).   AR09.10-P-1150Q
3 Release fuel pressure through service valve (5) at fuel rail (4) IMPORTANT Unscrew cap and catch fuel.  
    SPECIAL TOOL Figure
4 Dismount fuel feed line (2) from fuel distributor (4) IMPORTANT Collect fuel.  
5 Dismount bracket of engine wiring harness    
6 Separate electrical connectors (6) from fuel injection valves (Y62) IMPORTANT Carefully disconnect electrical connectors (6) (risk of cracks and fracture).  
7 Remove bolts (3)    
8 Raise fuel distributor (4) together with fuel injection valves (Y62) evenly off cylinder head    
INSPECT Checking     
9 Check O-rings of fuel injection valves (Y62) for damage IMPORTANT If necessary, replace the O-rings of the fuel injection valves (Y62).  
10 Test fuel injectors (Y62) IMPORTANT Defective fuel injection valves (Y62) must be replaced:
↓		  
    Remove/install injection valves. AR07.03-P-6522Q 
INSTALLING Install     
11 Install fuel distributor (4) together with fuel injection valves (Y62) IMPORTANT Lightly moisten O-rings with liquid lubricant.  
    Lubricant *BR00.45-Z-1002-06A 
12 Screw in screws (3) TORQUE SPECIFICATION Bolt, fuel distributor to cylinder head *BA07.52-P-1001-01B 
13 Plug electrical connectors (6) onto fuel injection valves (Y62)    
14 Fit bracket of engine wiring harness    
15 Fit fuel feed line (2) to fuel distributor (4) TORQUE SPECIFICATION *BA07.52-P-1002-01B 
16 Close off service valve (5) at fuel distributor (4)    
17 Install air filter housing (1) IMPORTANT Moisten rubber mounts slightly with lubricant. AR09.10-P-1150Q
    Lubricant *BR00.45-Z-1002-06A 
18 Read out fault memory and erase IMPORTANT Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in the fault memories after completing the work.  
REFER TO SELF-DIAGNOSTIC SYSTEMS Connect STAR DIAGNOSIS and read out fault memory   AD00.00-P-2000-04A
19 Close engine hood Model 203 AR88.40-P-1000P
    Model 209 AR88.40-P-1000Q
TORQUE SPECIFICATION FUEL DISTRIBUTOR

Number Designation Engine 271
BA07.52-P-1001-01B Bolt, fuel rail to cylinder head Stage 1 Nm 14
Stage 2 ∠ ° -
BA07.52-P-1002-01B Fuel feed line to fuel distributor   Nm 24
Fig 2: Identifying Pressure Hose (119 589 04 63 00)
G04737001
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1002-06A Lubricant A 000 989 01 60
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