Remove/Install Fuel Injectors - AR07.03-P-0004GQ

ENGINE 157, 276, 278 in MODEL 166 

ENGINE 157, 276, 278 in MODEL 292 

ENGINE 276 in MODEL 251 

22.02.2017

Stop plug new, added.

Operation step 4

270 589 03 91 00

Shown on model 166.062 with engine 276.821 

Courtesy of MERCEDES-BENZ USA

Shown on model 166.062 with engine 276.821 

Courtesy of MERCEDES-BENZ USA

	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
	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/install
1	Disconnect battery ground line	Engine 157, 276, 278 in model 166 Engine 157, 276, 278 in model 292	AR54.10-P-0003GZ
		Engine 276 in model 251	AR54.10-P-0003RT
2	Remove left or right rail (1)	Engine 157, 278 in model 166 Engine 157, 278 in model 292	AR07.03-P-1010MLJ
		Engine 276 in model 166, 251, 292 Only install upper engine cover after the leak test.	AR07.03-P-1010GQ
3	Mark fuel injectors (Y76) relative to the respective cylinder	If fuel injectors (Y76) are replaced, the transport protective caps on the fuel injectors (Y76) should not be removed until one hour before assembly at the earliest. Leaks can occur otherwise. When reusing the fuel injectors (Y76) they must be inserted into the cylinder in which the fuel injectors (Y76) were previously installed.
4	Pull out fuel injectors (Y76) from cylinder head and close off injector shaft bores with stop plugs	The fuel injectors (Y76) must be installed together with the rail (1). Plug	Fig 1
		For a jammed in fuel injector (Y76) ↓ Remove injection nozzle (Y76).	AR07.03-P-0004-03MM
		Puller	Fig 2
5	Check fuel injectors (Y76) for external damage	In a case of damage to the stems or to the mounts of the sealing package on the fuel injectors (Y76) ↓ Replace the affected fuel injector (Y76).
6	Replace sealing rings (2) and seals (4) on the fuel injectors (Y76)
7	Replace sealing rings (3) for fuel injectors (Y76)	Fuel injectors (Y76) must be installed immediately after calibration of the sealing rings (3). The sealing rings (3) will swell otherwise under the influence of the air humidity and will therefore be damaged in during assembly.	AR07.03-P-0004-01MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Assembly tool	Fig 3
8	Install in the reverse order
	Check
9	Store injector quantity compensation (IMA) coding in engine management control unit	For installation of new fuel injectors (Y76).
			AD00.00-P-2000-04A
	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 buttoned-up and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
10	Carry out an engine test run, checking the engine for proper operation and leaktightness
11	Read out and erase fault memory
			AD00.00-P-2000-04A
12	Install upper engine cover

Fig 1: Identifying Plug (270 589 03 91 00)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Puller (278 589 00 33 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA