Remove/Install Fuel Rail With Injectors For Cylinders 1, 2, 3 - AR07.03-P-1053MSC

Engine 256.9 in model 167

MODIFICATION NOTES

11.12.2019

Union nut, high-pressure line to fuel distributor/fuel high-pressure pump

BA07.03-P-1001-01MRT

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	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	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
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		AH07.00-P-2000-01A
	injection system
	Remove
1	Disconnect ground line from battery.		AR54.10-P-0003ME
2	Remove upper engine cover.	: Only install upper engine	AR01.10-P-2405MSC
		cover after the leak test.
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 air filter housing.		AR09.10-P-1150MSC
6	Remove fuel pressure via the service connection.		AR07.03-P-1460-04MSC
		Cap on service connection	*BA07.03-P-1009-01MRT
		Pressure hose	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 e sensor (B4/25).
9	Release and disconnect electrical connectors at fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3).
10	Remove engine wiring harness from front rail (1).
11	Remove high-pressure line (3) and seal openings with suitable stop plugs.	Box wrench bit	Fig 4
		Record plug	Fig 2
12	Mark fuel injectors for cylinders 1 to 3 (Y76/1 - Y76/3) relative to the corresponding cylinder.	When reusing the fuel injectors, insert cylinders 1 to 3 (Y76/1 to Y76/3) 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.	Record plug	Fig 2
16	Remove fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3) and seal injector shaft holes with suitable stop plugs.		AR07.03-P-0004-03MM
		Engine oil that escapes during disassembly of the fuel injectors for cylinders to 3 (Y76/1 to Y76/3) is safe. Re-use fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3).
		Plug	Fig 1
		Puller	Fig 5
17	Remove pressure and temperature sensor fuel (B4/25).	When replacing the front rail (1).
			AR07.04-P-0091MSC
	Check
18	Check the high-pressure line (3).		AR07.03-P-1010-03MRT
		Assembly cleaner If there are problems, ↓ Then replace the high-pressure line (3).	*BR00.45-Z-1028-04A
19	Check fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3) for external damage, and replace them if necessary.
	Clean
20	Clean fuel connections on fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3).	For cleaning the fuel connections, hold downwards. Otherwise, the fuel injectors for cylinders 1 to 3 (Y76/1 to 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
		Drift	Fig 7
22	Replace sealing rings (8, 9) of the fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3).
23	Replace sealing rings (10) of the fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3).		AR07.03-P-0004-01MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Assembly tool	Fig 3
24	Install fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3) in the front rail (1) and secure them with hold-down tools (7a).	When reusing the fuel injectors, insert cylinders 1 to 3 (Y76/1 to Y76/3) into the cylinders in which they were previously installed. Engine damage will occur otherwise. Replace hold-down tools (7a).
25	Install the front rail (1) with fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3).
26	Tighten screws (6a).	Screw/bolt, fuel distributor to cylinder head cover	*BA07.52-P-1001-01G
27	Install high-pressure line (3).
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
		Do not bend or kink high-pressure line (3). Leaks can occur otherwise.
		Union nut, high-pressure line to fuel distributor/fuel high-pressure pump	*BA07.03-P-1001-01MRT
		Record plug	Fig 2
		Box wrench bit	Fig 4
28	Install fuel pressure and temperature sensor (B4/25).	When replacing the front rail (1).
			AR07.04-P-0091MSC
29	Connect and lock electrical connector of fuel pressure and temperature e sensor (B4/25).
30	Install engine wiring harness on front rail (1).
31	Connect and lock electrical connectors of the fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3).
32	Install air filter housing.		AR09.10-P-1150MSC
33	Install front noise insulation.
34	Connect ground line to battery.		AR54.10-P-0003ME
35	Store injector injection quantity adjustment coding in ME-SFI [ME] control unit.	When replacing the fuel injectors for cylinders 1 to 3 (Y76/1 to Y76/3).
			AD00.00-P-2000-06ME
	Check
36	Check high-pressure fuel circuit for leak tightness.
			AD00.00-P-2000-06ME
			AR07.03-P-1010-04MM
37	Carry out engine test run and check engine for proper leaktightness and leaktightness.
38	Install upper engine cover.		AR01.10-P-2405MSC

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
		For new lines	Stage 2	∠°	90