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Home >> Mercedes Benz >> 2021 >> CLS450 Base >> Repair and Diagnosis >> Engine Performance >> Tune-Up >> Mixture Formation - 257 Chassis 1 Of 2 >> Testing & Repair >> Remove/Install Rail With Fuel Injectors For Cylinders 4, 5, 6 - AR07.03-P-1054MSA

Remove/Install Rail With Fuel Injectors For Cylinders 4, 5, 6 - AR07.03-P-1054MSA

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
G14548172Courtesy of MERCEDES-BENZ USA
G14548173Courtesy of MERCEDES-BENZ USA
WARNING 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
DANGER 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 
DANGER 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
CAUTION 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
Topical note  Notes on threaded connections fastened using a tightening angle-based tightening process   AH00.00-P-0020-01A
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 
  Note on calculation of tightening torque when using insertion or socket tools with various effective lengths   AH00.00-P-0015-01CW
REMOVING 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 the oil separator.   AR01.20-P-9750MSA
3 Remove engine air intake duct downstream of air filter.   AR09.10-P-8130MSA
4 Remove rear noise insulation.    
5 Clean area around front rail (1), rear rail (2) and high-pressure lines (3, 4). Assembly cleaner *BR00.45-Z-1028-04A 
6 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
7 Remove fuel pressure via the service connection.   AR07.03-P-1460-01MSA 
    TORQUE SPECIFICATION Cap on service connection *BA07.03-P-1009-01MRT 
    SPECIAL TOOL Pressure hose Fig 6
8 Release fuel pressure in the fuel high-pressure circuit.   AR07.03-P-1460-02MM 
9 Release and disconnect electrical connectors of fuel injectors (Y76/4, Y76/5, Y76/6).    
10 Remove engine wiring harness from rear rail (2).    
11 Remove high-pressure line (3) and seal openings with suitable stop plugs. SPECIAL TOOL Box wrench bit Fig 4
    SPECIAL TOOL Record plug Fig 2
12 Remove screw (5).    
13 Remove high-pressure line (4) from rear rail (2).   AR07.03-P-1003MSA 
14 Mark fuel injectors (Y76/4, Y76/5, Y76/6) relative to the corresponding cylinder. NOTES When reusing the fuel injectors (Y76/4, Y76/5 Y76/6), insert them into the cylinders in which they were previously installed.
Engine damage will occur otherwise.		  
15 Remove screws (6b).    
16 Remove hold-down tools (7b).    
17 Remove rear rail (2) and seal openings with suitable stop plugs. SPECIAL TOOL Record plug Fig 2
18 Remove fuel injectors (Y76/4, Y76/5, Y76/6) and seal injector shaft holes with suitable stop plugs.   AR07.03-P-0004-03MM 
    IMPORTANT Engine oil that escapes during disassembly of the fuel injectors (Y76/4, Y76/5, Y76/6) is safe. Reuse the fuel injectors (Y76/4, Y76/5, Y76/6).  
    SPECIAL TOOL Plug Fig 1
    SPECIAL TOOL Puller Fig 5
INSPECT Check     
19 Check high-pressure lines (3, 4) and replace if necessary.   AR07.03-P-1010-03MRT 
    Assembly cleaner *BR00.45-Z-1028-04A 
20 Check fuel injectors (Y76/4, Y76/5, Y76/6) for external damage and replace if necessary.    
CLEAN Clean     
21 Clean fuel connections on fuel injectors (Y76/4, Y76/5, Y76/6). NOTES For cleaning the fuel connections, hold downwards.
Otherwise the fuel injectors (Y76/4, Y76/5, Y76/6) will fail.		  
    Assembly cleaner *BR00.45-Z-1028-04A 
INSTALLING Install     
22 Replace sealing packages for rear rail (2).   AR07.03-P-0004-02MM 
    Assembly cleaner *BR00.45-Z-1028-04A 
    SPECIAL TOOL Drift Fig 7
23 Replace sealing rings (8, 9) of fuel injectors (Y76/4, Y76/5, Y76/6).    
24 Replace sealing rings (10) of fuel injectors (Y76/4, Y76/5, Y76/6).   AR07.03-P-0004-01MM 
    Assembly cleaner *BR00.45-Z-1028-04A 
    SPECIAL TOOL Assembly tool Fig 3
25 Install fuel injectors (Y76/4, Y76/5, Y76/6) in rear rail (2) and fasten with hold-down tools (7a). NOTES When reusing the fuel injectors (Y76/4, Y76/5 Y76/6), insert them into the cylinders in which they were previously installed.
Engine damage will occur otherwise.
IMPORTANT Replace hold-down tools (7).		  
26 Install rear rail (2) with fuel injectors (Y76/4, Y76/5, Y76/6).    
27 Tighten screws (6b). TORQUE SPECIFICATION Screw/bolt, fuel distributor to cylinder head cover *BA07.52-P-1001-01G 
28 Install high-pressure line (3). NOTES Do not bend or kink high-pressure line (3). Leaks can occur otherwise.  
    TORQUE SPECIFICATION Union nut, high-pressure line to fuel distributor/fuel high-pressure pump *BA07.03-P-1001-01MRT 
    SPECIAL TOOL Record plug Fig 2
    SPECIAL TOOL Box wrench bit Fig 4
29 Mount high-pressure line (4) to rear rail (2).   AR07.03-P-1003MSA 
30 Tighten screw (5). TORQUE SPECIFICATION Bolt, holder for high-pressure line to camshaft housing/cylinder head *BA07.03-P-1004-01MRT 
31 Install engine wiring harness on rear rail (2).    
32 Connect and lock electrical connectors of fuel injectors (Y76/4, Y76/5, Y76/6).    
33 Install rear noise insulation.    
34 Install oil separator.   AR01.20-P-9750MSA
    INSTALLATION IMPORTANT Only install upper engine cover after the leak test.  
35 Install engine air intake duct downstream of ail filter.   AR09.10-P-8130MSA
36 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
37 Store injector quantity compensation coding in ME-SFI [ME] control unit. When replacing the fuel injectors (Y76/4, Y76/5, Y76/6).  
REFER TO SELF-DIAGNOSTIC SYSTEMS   Engine 256.9 in model 213 AD00.00-P-2000-04B
REFER TO SELF-DIAGNOSTIC SYSTEMS   Engine 256.9 in model 238 AD00.00-P-2000-06LWO
REFER TO SELF-DIAGNOSTIC SYSTEMS   Engine 256.9 in model 257, 290 AD00.00-P-2000-06FR
INSPECT Check     
38 Check fuel high-pressure circuit for leak tightness.   AR07.03-P-1010-04MM 
REFER TO SELF-DIAGNOSTIC SYSTEMS   Engine 256.9 in model 213 AD00.00-P-2000-04B
REFER TO SELF-DIAGNOSTIC SYSTEMS   Engine 256.9 in model 238 AD00.00-P-2000-06LWO
REFER TO SELF-DIAGNOSTIC SYSTEMS   Engine 256.9 in model 257, 290 AD00.00-P-2000-06FR
39 Carry out engine test run and check engine for proper leaktightness and leaktightness.    
40 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
41 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-1004-01MRT Bolt, holder for high-pressure line to camshaft housing/cylinder head Nm 8
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
Fig 1: Identifying Plug (270 589 03 91 00)
G11974108Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Record Plug (129 589 00 91 00)
G11972128Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Assembly Tool (272 589 00 43 00)
G13655951Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Box Wrench Bit (000 589 69 03 00)
G13743490Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Puller (278 589 00 33 00)
G11128361Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Pressure Hose (119 589 04 63 00)
G12078803Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Drift (278 589 01 15 00)
G13655990Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1028-04A Assembly cleaner A 000 986 56 01
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