Remove/Install Fuel Rail With Fuel Injectors - AR07.03-P-1052MRH
Engine 264 in Model 213, 238, 257
MODIFICATION NOTES
| 05.12.2019 | Document completely revised. | ||
| 25.04.2021 | Cooling system | BF20.00-P-1001-06D |
Shown on model 238 with engine 264
Fig 1: Fuel Rail With Fuel Injectors Components Location - Engine 264 In Model 213 (Shown On Model 238)
Shown on model 238 with engine 264
| Risk of explosion caused by igniting fuel.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 explosion caused by fuel igniting, Risk of poisoning cause by inhaling and swallowing fuel as well as Risk of injury to skin and eyes 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 | |
| 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 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 the vehicle to prevent it from starting by itself. Wear closed, close and snug fitting work clothing. Do not touch hot or rotating parts. | AS00.00-Z-0005-01A | |
| Risk of injury to skin and eyes from handling engine oil. Risk of poisoning caused by swallowing engine oil. | Wear protective gloves, protective clothing and protective goggles. Do not fill engine oil into beverage containers. |
AS18.00-Z-0001-01A | |
| NOTICE | Notes on coolant | AH20.00-N-2080-01A | |
| NOTICE | Information on avoiding damage to electronic components through electrostatic discharge | AH54.00-P-0001-01A | |
| NOTICE | Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | |
| NOTICE | Notes on avoiding damage from 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 | ||
| Notes on safety-relevant components | AH00.00-Z-0019-01A | ||
| Remove | |||
| 1 | Relieve fuel pressure using diagnostic system. | ||
| Engine 264 in Model 213 | AD00.00-P-2000-04B | ||
| Engine 264 in Model 238 | AD00.00-P-2000-06LWO | ||
| Engine 264 in Model 257 ME-SFI [ME] control unit → Actuation → Actuate the fuel pump. |
AD00.00-P-2000-06FR | ||
| 2 | Remove ground line of battery. | Engine 264 in Model 213 | AR54.10-P-0003LW |
| Engine 264 in Model 238 | AR54.10-P-0003LWO | ||
| Engine 264 in Model 257 | AR54.10-P-0003FR | ||
| 3 | Remove rear engine cover. | AR01.10-P-2408MRH | |
| Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray.Risk of poisoning from swallowing coolant | Open the cooling system only if the coolant temperature is below 90 ° C. Open cap slowly and release the excess pressure. Do not pour cool liquid into drinking containers. Wear protective gloves, protective clothing and safety glasses. |
AS20.00-Z-0001-01A | |
| 4 | Remove engine wiring harness. | Do not kink or subject lines to tension. Otherwise damage will occur. |
AR15.18-P-1000-04MRH |
| Fig 4 | |||
| Fig 2 | |||
| 5 | Remove shield (1). | Tightening procedure for high-pressure pump shielding |
AR07.02-P-0815-01MRH |
| 6 | Remove soundproofing for high-pressure pump. | ||
| 7 | Clean the area around the high pressure pump, the high pressure line (2) and the rail (3). | Assembly cleaner | *BR00.45-Z-1028-04A |
| 8 | Release the fuel pressure in the fuel high-pressure circuit. | AR07.03-P-1460-02MM | |
| 9 | Remove high-pressure line (2) and seal connections with suitable stop plugs. | Do not kink or bend high-pressure line (2). Leaks can occur otherwise. |
|
| Fig 7 | |||
| Fig 4 | |||
| 10 | Remove the intake camshaft valve lift changeover actuator (Y49/8). | AR05.20-P-6560MRH | |
| 11 | Mark the fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4) to indicate the corresponding cylinder. | When reusing the fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4). When reusing, insert the fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4) into the cylinder in which they were previously installed. Otherwise engine damage will occur. |
|
| 12 | Remove hold-down tools (4). | ||
| 13 | Unscrew the screws of the rail (3) in the reverse order of the tightening procedure. | Rail tightening procedure | AR07.03-P-1010-06MRH |
| 14 | Remove the rail (3) and seal the connections with suitable stop plugs. | Make sure it is extremely clean. Otherwise, leaks and malfunctions will occur. |
|
| Fig 4 | |||
| 15 | Pull the fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4) out of the cylinder head and seal the injector shaft bores with suitable plugs. | AR07.03-P-0004-03MM | |
| Fig 3 | |||
| Fig 6 | |||
| 16 | Remove fuel pressure and temperature sensor (B4 / 25). | When renewing the rail (3). | AR07.04-P-0093MRH |
| Check | |||
| 17 | Check fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4) for external damage and replace if necessary. | When reusing the fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4). If new fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) are to be installed, they must be installed immediately after removing the transport protection caps. Leaks can occur otherwise. |
|
| 18 | Check high pressure line (2). | AR07.03-P-1010-03MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Clean | |||
| 19 | Clean fuel connections on fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4). | When reusing the Fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4). Hold the fuel connections down when cleaning. Otherwise the fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4) may fail. |
|
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Install | |||
| 20 | Replace sealing package of rail (3). | AR07.03-P-0004-02MM | |
| Fig 8 | |||
| 21 | Install new sealing rings (5, 6) of the fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4). | When reusing the Fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4). |
|
| 22 | Replace the sealing rings (7) of the fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4). | When reusing the Fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4). |
AR07.03-P-0004-01MM |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 5 | |||
| 23 | Install fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4) in the rail (3) and secure with new hold-downs (4). | When reusing, insert the fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4) into the cylinder in which they were previously installed. Otherwise engine damage will occur. |
|
| 24 | Remove stop plugs from the injector well bores. | Fig 3 | |
| 25 | Install the rail (3) with fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4). | ||
| 26 | Tighten the screws of the rail (3). | Rail tightening procedure | AR07.03-P-1010-06MRH |
| *BA07.52-P-1001-01K | |||
| 27 | Install fuel pressure and temperature sensor (B4 / 25). | When installing new rail (3). | AR07.04-P-0093MRH |
| 28 | Install high pressure line (2). | Do not bend or kink the high pressure line (2). Otherwise there will be leaks. |
|
| *BA07.03-P-1001-01I | |||
| Fig 7 | |||
| 29 | Install the intake camshaft valve lift changeover actuator (Y49/8). | AR05.20-P-6560MRH | |
| 30 | Install soundproofing for high-pressure pump. | ||
| 31 | Install shielding (1). | Tightening procedure for high pressure pump shielding | AR07.02-P-0815-01MRH |
| *BA07.02-P-1002-02A | |||
| Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray.Risk of poisoning from swallowing coolant | Open the cooling system only at coolant temperatures below 90 ° C. Slowly open the cap and release the excess pressure. Do not pour cool liquid into drinking containers. Wear protective gloves, protective clothing and protective goggles. |
AS20.00-Z-0001-01A | |
| 32 | Install engine wiring harness. | AR15.18-P-1000-04MRH | |
| Notes on coolant level | AH20.00-P-1142-01CW | ||
| *BF20.00-P-1001-06D | |||
| *BA00.10-P-1002-04A | |||
| Fig 4 | |||
| Fig 2 | |||
| 33 | Check engine cooling system for leaks. | AR20.00-P-1011OLC | |
| 34 | Connect ground line to battery | Engine 264 in Model 213 | AR54.10-P-0003LW |
| Engine 264 in Model 238 | AR54.10-P-0003LWO | ||
| Engine 264 in Model 257 | AR54.10-P-0003FR | ||
| 35 | Read out the fault memory with the vehicle diagnosis system and delete if necessary. | ||
| Engine 264 in Model 213 | AD00.00-P-2000-04B | ||
| Engine 264 in Model 238 | AD00.00-P-2000-06LWO | ||
| Engine 264 in Model 257 | AD00.00-P-2000-06FR | ||
| 36 | Store injector quantity compensation (IMA) - coding in the engine control module (MCM). | When installing new fuel injectors (Y76 / 1, Y76 / 2, Y76 / 3, Y76 / 4). | |
| Engine 264 in Model 213 | AD00.00-P-2000-04B | ||
| Engine 264 in Model 238 | AD00.00-P-2000-06LWO | ||
| Engine 264 in Model 257 | AD00.00-P-2000-06FR | ||
| 37 | Check fuel high pressure circuit. | AR07.03-P-1010-04MM | |
| Engine 264 in Model 213 | AD00.00-P-2000-04B | ||
| Engine 264 in Model 238 | AD00.00-P-2000-06LWO | ||
| Engine 264 in Model 257 | AD00.00-P-2000-06FR | ||
| 38 | Carry out engine test run, check engine for function and leaks. | ||
| 39 | Install rear engine cover. | AR01.10-P-2408MRH |
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 FUEL PUMP
| Number | Designation | Engine 264 | |
|---|---|---|---|
| BA07.02-P-1002-02A | Bolt for high-pressure pump shielding | Nm | 20 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 264 | ||
|---|---|---|---|---|
| BA07.03-P-1001-01I | Union nut for fuel line to high pressure pump / fuel distributor | Stage 1 | Nm | 15 |
| Stage 2 | ∠° | 75 | ||
| Stage 3 | ∠° | 25 | ||
FUEL DISTRIBUTOR
| Number | Designation | ||
|---|---|---|---|
| BA07.52-P-1001-01K | Screw/bolt, fuel distributor to cylinder head cover | Nm | 8 |
COOLING SYSTEM
| Number | Designation | Engine 264 in Model 213 | Engine 264 in Model 238.377/378/380/38 3/387/477/478/480/4 83/487 | |||
|---|---|---|---|---|---|---|
| BF20.00-P-1001-06D | cooling system | Workshop replacement amount. | Main circuit | Liter | ≈ 11, 0 | ≈ 9, 0 |
| Low-temperature circuit | Liter | - | - | |||
| Antifreeze / water | Down to -37°C | % | 50/50 | 50/50 | ||
| -38 °C and below | % | 55/45 | 55/45 | |||
| Specifications for Operating Fluids, sheet | BB00.40-P-0310-01A | BB00.40-P-0310-01A | ||||
| Specifications for Operating Fluids, sheet | BB00.40-P-0325-06A | BB00.40-P-0325-06A | ||||
| Specifications for Operating Fluids, sheet | BB00.40-P-0326-06A | BB00.40-P-0326-06A | ||||
COOLING SYSTEM
| Number | Designation | Engine 264 in Model 238.385/386/485 | Engine 264 in Model 257.348 | |||
|---|---|---|---|---|---|---|
| BF20.00-P-1001-06D | cooling system | Workshop replacement amount. | Main circuit | Liter | ≈ 10, 0 | ≈ 14, 0 |
| Low-temperature circuit | Liter | - | - | |||
| Antifreeze / water | Down to -37°C | % | 50/50 | 50/50 | ||
| -38 °C and below | % | 55/45 | 55/45 | |||
| Specifications for Operating Fluids, sheet | BB00.40-P-0310-01A | BB00.40-P-0310-01A | ||||
| Specifications for Operating Fluids, sheet | BB00.40-P-0325-06A | BB00.40-P-0325-06A | ||||
| Specifications for Operating Fluids, sheet | BB00.40-P-0326-06A | BB00.40-P-0326-06A | ||||
COOLING SYSTEM
| Number | Designation | Engine 264 in Model 257 (except 257.348) | |||
|---|---|---|---|---|---|
| BF20.00-P-1001-06D | cooling system | Workshop replacement amount. | Main circuit | Liter | ≈ 9, 0 |
| Low-temperature circuit | Liter | ≈ 4, 0 | |||
| Antifreeze / water | Down to -37°C | % | 50/50 | ||
| -38 °C and below | % | 55/45 | |||
| Specifications for Operating Fluids, sheet | BB00.40-P-0310-01A | ||||
| Specifications for Operating Fluids, sheet | BB00.40-P-0325-06A | ||||
| Specifications for Operating Fluids, sheet | BB00.40-P-0326-06A | ||||
REPAIR MATERIALS
| Number | Description | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |