Remove/Install Rail With Fuel Injectors For Cylinders 1, 2, 3 - AR07.03-P-1053MSA
Engine 256.9 in model 213, 238, 257, 290
MODIFICATION NOTES
| 11.12.2019 | Union nut, high-pressure line to fuel distributor/fuel high-pressure pump | BA07.03-P-1001-01MRT |
| 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 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 | |
| Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil | Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers. |
AS18.00-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 | |
| Topical note | Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | |
| Notes on injectors | AH07.16-P-1000-01MRT | ||
| General information on work on gasoline direct injection system | AH07.00-P-2000-01A | ||
| Remove | |||
| 1 | Disconnect ground line from battery. | Engine 256.9 in model 213 | AR54.10-P-0003LW |
| Engine 256.9 in model 238 | AR54.10-P-0003LWO | ||
| Engine 256.9 in model 257, 290 | AR54.10-P-0003FR | ||
| 2 | Remove upper engine cover. | AR01.10-P-2405MSA | |
| 3 | Remove front noise insulation. | ||
| 4 | Clean area around front rail (1) and high-pressure line (3). | Assembly cleaner | *BR00.45-Z-1028-04A |
| 5 | Remove center and rear sections of lower engine compartment lining. | Engine 256.9 in model 213, 238 | AR61.20-P-1105LWE |
| Engine 256.9 in model 257 | AR61.20-P-1105FR | ||
| Engine 256.9 in model 290 | AR61.20-P-1105FRX | ||
| 6 | Relieve fuel pressure via service connection. | AR07.03-P-1460-01MSA | |
| *BA07.03-P-1009-01MRT | |||
| Fig 6 | |||
| 7 | Release fuel pressure in the fuel high-pressure circuit. | AR07.03-P-1460-02MM | |
| 8 | Release and disconnect electrical connection at fuel pressure and temperature sensor (B4/25). | ||
| 9 | Release and disconnect electrical connectors of fuel injectors (Y76/1, Y76/2, Y76/3). | ||
| 10 | Remove engine wiring harness from front rail (1). | ||
| 11 | Remove high-pressure line (3) and seal openings with suitable stop plugs. | Fig 4 | |
| Fig 2 | |||
| 12 | Mark fuel injectors (Y76/1, Y76/2, Y76/3) relative to the corresponding cylinder. | When reusing the fuel injectors (Y76/1, Y76/2, Y76/3), insert them into the cylinders in which they were previously installed. Engine damage will occur otherwise. |
|
| 13 | Remove screws (6a). | ||
| 14 | Remove hold-down tools (7a). | ||
| 15 | Remove front rail (1) and seal openings with suitable stop plugs. | Fig 2 | |
| 16 | Remove fuel injectors (Y76/1, Y76/2, Y76/3) and seal injector shaft holes with suitable stop plugs. | AR07.03-P-0004-03MM | |
| Fig 1 | |||
| Fig 5 | |||
| 17 | Remove fuel pressure and temperature sensor (B4/25). | When replacing the front rail (1). | |
| AR07.04-P-0091MSA | |||
| Check | |||
| 18 | Check high-pressure line (3) and replace if necessary. | AR07.03-P-1010-03MRT | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| 19 | Check fuel injectors (Y76/1, Y76/2, Y76/3) for external damage and replace if necessary. | ||
| Clean | |||
| 20 | Clean fuel connections on fuel injectors (Y76/1, Y76/2, Y76/3). | For cleaning the fuel connections, hold downwards. Otherwise the fuel injectors (Y76/1, Y76/2, Y76/3) will fail. |
|
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Install | |||
| 21 | Replace sealing packages of front rail (1). | AR07.03-P-0004-02MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 7 | |||
| 22 | Replace sealing rings (8, 9) of fuel injectors (Y76/1, Y76/2, Y76/3). | ||
| 23 | Replace sealing rings (10) of fuel injectors (Y76/1, Y76/2, Y76/3). | AR07.03-P-0004-01MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 3 | |||
| 24 | Install fuel injectors (Y76/1, Y76/2, Y76/3) in front rail (1) and fasten with hold-down tools (7a). | When reusing the fuel injectors (Y76/1, Y76/2, Y76/3), insert them into the cylinders in which they were previously installed. Engine damage will occur otherwise. |
|
| 25 | Install front rail (1) with fuel injectors (Y76/1, Y76/2, Y76/3). | ||
| 26 | Tighten screws (6a). | *BA07.52-P-1001-01G | |
| 27 | Install high-pressure line (3). Notes on threaded connections fastened using a tightening angle-based tightening process |
AH00.00-P-0020-01A | |
| Topical note | Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | AH00.00-P-0015-01CW | |
Do not bend or kink high-pressure line (3). Leaks can occur otherwise. |
|||
| *BA07.03-P-1001-01MRT | |||
| Fig 2 | |||
| Fig 4 | |||
| 28 | Install fuel pressure and temperature sensor (B4/25). | When replacing the front rail (1). | |
| AR07.04-P-0091MSA | |||
| 29 | Connect and lock electrical connector of fuel pressure and temperature sensor (B4/25). | ||
| 30 | Install engine wiring harness on front rail (1). | ||
| 31 | Connect and lock electrical connectors of fuel injectors (Y76/1, Y76/2, Y76/3). | ||
| 32 | Install front noise insulation. | ||
| 33 | Connect ground line to battery. | Engine 256.9 in model 213 | AR54.10-P-0003LW |
| Engine 256.9 in model 238 | AR54.10-P-0003LWO | ||
| Engine 256.9 in model 257, 290 | AR54.10-P-0003FR | ||
| 34 | Store injector quantity compensation coding in ME-SFI [ME] control unit. | When replacing the fuel injectors (Y76/1, Y76/2, Y76/3). | |
| Engine 256.9 in model 213 | AD00.00-P-2000-04B | ||
| Engine 256.9 in model 238 | AD00.00-P-2000-06LWO | ||
| Engine 256.9 in model 257, 290 | AD00.00-P-2000-06FR | ||
| Check | |||
| 35 | Check fuel high-pressure circuit for leak tightness. | AR07.03-P-1010-03MRT | |
| Engine 256.9 in model 213 | AD00.00-P-2000-04B | ||
| Engine 256.9 in model 238 | AD00.00-P-2000-06LWO | ||
| Engine 256.9 in model 257, 290 | AD00.00-P-2000-06FR | ||
| 36 | Carry out engine test run and check engine for proper operation and leak tightness. | ||
| 37 | Install center and rear lower engine compartment lining. | Engine 256.9 in model 213, 238 | AR61.20-P-1105LWE |
| Engine 256.9 in model 257 | AR61.20-P-1105FR | ||
| Engine 256.9 in model 290 | AR61.20-P-1105FRX | ||
| 38 | Install upper engine cover. | AR01.10-P-2405MSA |
HIGH-PRESSURE LINE, LOW-PRESSURE LINE, FUEL DISTRIBUTOR
| Number | Designation | Engine 256.9 | |||
|---|---|---|---|---|---|
| BA07.03-P-1001-01MRT | Union nut, high-pressure line to fuel distributor/fuel high-pressure pump | In case of reusability | Nm | 18 | |
| For new lines | Stage 1 | Nm | 15 | ||
| Stage 2 | ∠° | 90 | |||
HIGH-PRESSURE LINE, LOW-PRESSURE LINE, FUEL DISTRIBUTOR
| Number | Designation | Engine 256.9 | ||
|---|---|---|---|---|
| BA07.03-P-1009-01MRT | Cap on service connection | Plastic | Nm | 1 |
FUEL DISTRIBUTOR
| Number | Designation | Engine 256.9 | |
|---|---|---|---|
| BA07.52-P-1001-01G | Screw/bolt, fuel distributor to cylinder head cover | Nm | 14 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |