Remove/Install Fuel Rail With Fuel Injectors - AR07.03-P-1052MRA
Engine 274.9 in model 205
Engine 274.9 in model 253
| 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 caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. |
AS00.00-Z-0017-01A | |
| 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 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 | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | ||
| Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | ||
| Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | AH00.00-P-0015-01CW | ||
| General information on work on gasoline direct injection system | AH07.00-P-2000-01A | ||
| Remove | |||
| 1 | Remove center and rear lower engine compartment paneling | Vehicle with diagnostic socket. | AR61.20-P-1105LW |
| 2.1 | Relieve fuel pressure over diagnostic socket | Vehicle with diagnostic socket. | |
| AR07.03-P-1460-01MR | |||
| *BA07.03-P-1003-01F | |||
| Fig 8 | |||
| 2.2 | Relieve fuel pressure over diagnostic system | Vehicle without diagnostic socket. | |
| AD00.00-P-2000-04B | |||
ME-SFI [ME] control unit → Actuation → Actuate the fuel pump. |
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| 3 | Disconnect ground line from battery | AR54.10-P-0003LW | |
| 4 | Remove upper engine cover | ||
| 5 | Disconnect engine wiring harness and remove | AR15.18-P-1000-04LWA | |
| 6 | Detach shielding (5) in reverse order to tightening procedure and remove | Tightening procedure for high-pressure pump shielding | AR07.02-P-0815-01MR |
| 7 | Remove soundproofing for high-pressure pump | ||
| 8 | Clean area around high-pressure pump and high-pressure line (7) | Failure of the fuel injection system can occur otherwise. |
|
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 9 | Relieve fuel pressure in fuel system high-pressure circuit | AR07.03-P-1460-02MM | |
| 10 | Remove high-pressure line (7) and seal off connections using suitable stop plugs | Leaks can occur otherwise. |
|
| Fig 6 | |||
| Fig 3 | |||
| 11 | Unscrew screws (6) in reverse order to tightening procedure | Rail tightening procedure | AR07.03-P-1010-06MR |
| 12 | Remove hold-down tools between rail (8) and fuel injectors (Y76) | ||
| 13 | Mark fuel injectors (Y76) relative to the respective cylinder | Engine damage will occur otherwise. |
|
| 14 | Remove rail (8) from fuel injectors (Y76) and seal connections with suitable stop plugs | Fig 3 | |
| 15 | Pull out fuel injectors (Y76) from cylinder head and close off injector shaft bores with suitable stop plugs | AR07.03-P-0004-03MM | |
| Fig 5 | |||
| Fig 2 | |||
| Check | |||
| 16 | Check fuel injectors (Y76) for external damage and replace if necessary | Leaks can occur otherwise. |
|
| 17 | Check high-pressure line (7) for damage and replace if necessary | AR07.03-P-1010-03MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Clean | |||
| 18 | Clean fuel connections on fuel injectors (Y76) | Otherwise failure of the fuel injectors (Y76). Assembly cleaner |
*BR00.45-Z-1028-04A |
| 19 | Remove stop plugs of injector well bores | Fig 2 | |
| Install | |||
| 20 | Replace sealing packages of fuel injectors (Y76) at rail (8) | AR07.03-P-0004-02MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 9 | |||
| 21 | Replace sealing rings (2, 4) for fuel injectors (Y76) | ||
| 22 | Replace sealing rings (3) for fuel injectors (Y76) | AR07.03-P-0004-01MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 4 | |||
| 23 | Remove stop plugs, install fuel injectors (Y76) in rail (8) and secure with new hold-down tools | Engine damage will occur otherwise. |
|
| Fig 3 | |||
| 24 | Remove stop plugs and install rail (8) together with fuel injectors (Y76) | Fig 2 | |
| 25 | Tighten screw/bolts (6) | Rail tightening procedure | AR07.03-P-1010-06MR |
| *BA07.52-P-1001-01H | |||
| 26 | Remove stop plugs and install high-pressure line (7) | AR07.03-P-1010-02MR | |
Leaks can occur otherwise. |
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| *BA07.03-P-1001-01F | |||
| *BA07.03-P-1002-01F | |||
| Fig 6 | |||
| Fig 3 | |||
| 27 | Install soundproofing for high-pressure pump | ||
| 28 | Install shielding (5) | Tightening procedure for high-pressure pump shielding | AR07.02-P-0815-01MR |
| *BA07.02-P-1004-01D | |||
| Fig 7 | |||
| 29 | Attach engine wiring harness and connect | AR15.18-P-1000-04LWA | |
| *BA00.10-P-1002-04A | |||
| 30 | Connect ground lead to battery | AR54.10-P-0003LW | |
| 31 | Read out fault memory with vehicle diagnosis system and delete if necessary | AD00.00-P-2000-04B | |
| 32 | Store injection quantity compensation coding in motor control module (MCM) | For installation of new fuel injectors (Y76) |
AD00.00-P-2000-04B |
| Check | |||
| 33 | Check fuel high-pressure circuit for leaktightness | AR07.03-P-1010-04MM | |
| AD00.00-P-2000-04B | |||
| 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 | |
| 34 | Perform an engine test run and check engine for proper operation and leaktightness | ||
| 35 | Install center and lower engine compartment paneling | Vehicle with diagnostic socket. | AR61.20-P-1105LW |
| 36 | Install upper engine cover |
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-P-1002-04A | M6X1 | Nm | 9 | 13 |
HIGH PRESSURE PUMP
| Number | Designation | Engine 274 | |
|---|---|---|---|
| BA07.02-P-1004-01D | Bolt for high-pressure pump shielding | Nm | 20 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 274 | ||
|---|---|---|---|---|
| BA07.03-P-1001-01F | Union nut, fuel line to fuel distributor | Stage 1 | Nm | 15 |
| Stage 2 | ∠° | 75 | ||
| Stage 3 | ∠° | 25 | ||
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 274 | ||
|---|---|---|---|---|
| BA07.03-P-1002-01F | Union nut, fuel line to high-pressure pump | Stage 1 | Nm | 15 |
| Stage 2 | ∠° | 75 | ||
| Stage 3 | ∠° | 25 | ||
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 274 | ||
|---|---|---|---|---|
| BA07.03-P-1003-01F | Dust cap on service valve | Plastic | Nm | 2 |
| Metal | Nm | 15 | ||
FUEL DISTRIBUTOR
| Number | Designation | Engine 274 | |
|---|---|---|---|
| BA07.52-P-1001-01H | Screw/bolt, fuel distributor to cylinder head cover | Nm | 8 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | Adolf Wurth GmbH & Co. KG |