Remove/Install Fuel Rail With Injectors For Cylinders 4, 5, 6 - AR07.03-P-1054MSC
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 |
| 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 | |
| Risk of explosion
caused by fuel igniting. Risk of injury To skin and eyes cause 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 | |
| Topical note | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-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 | ||
| Remove | |||
| 1 | Disconnect ground line from battery. | AR54.10-P-0003ME | |
| 2 | Remove upper service flap. | AR01.10-P-2405-02MSC | |
| 3 | Remove the oil separator. | AR01.20-P-9750MSC | |
| 4 | Remove air filter housing. | AR09.10-P-1150MSC | |
| 5 | Remove engine air intake duct downstream of air filter. | AR09.10-P-8130MSC | |
| 6 | Remove rear noise insulation. | ||
| 7 | Clean area around front rail (1), rear rail (2) and high-pressure lines (3, 4). | Assembly cleaner | *BR00.45-Z-1028-04A |
| 8 | Remove fuel pressure via the service connection. | AR07.03-P-1460-04MSC | |
| *BA07.03-P-1009-01MRT | |||
| Fig 6 | |||
| 9 | Release fuel pressure in the fuel high-pressure circuit. | AR07.03-P-1460-02MM | |
| 10 | Release and disconnect electrical connectors of fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6). | ||
| 11 | Remove engine wiring harness from rear rail (2). | ||
| 12 | Remove high-pressure line (3) and seal openings with suitable stop plugs. | Fig 4 | |
| Fig 2 | |||
| 13 | Remove screw (5). | ||
| 14 | Remove high-pressure line (4) from rear rail (2). | AR07.03-P-1003MSC | |
| 15 | Mark fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6) relative to the corresponding cylinder. | When reusing, insert the fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6) into the cylinders in which they were previously installed. Engine damage will occur otherwise. |
|
| 16 | Remove screws (6b). | ||
| 17 | Remove hold-down tools (7b). | ||
| 18 | Remove rear rail (2) and seal openings with suitable stop plugs. | Fig 2 | |
| 19 | Remove fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6) and seal injector shaft holes with suitable stop plugs. | AR07.03-P-0004-03MM | |
| Fig 1 | |||
| Fig 5 | |||
| Check | |||
| 20 | Check high-pressure lines (3, 4). | AR07.03-P-1010-03MRT | |
| Assembly cleaner If there are problems, ↓ then replace high-pressure lines (3, 4). |
*BR00.45-Z-1028-04A | ||
| AR07.03-P-1003MSC | |||
| 21 | Check fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6) for external damage and replace them if necessary. | ||
| Clean | |||
| 22 | Clean fuel connections on fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6). | For cleaning the fuel connections, hold downwards. Otherwise, the fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6) will fail. |
|
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Install | |||
| 23 | Replace sealing packages for rear rail (2). | AR07.03-P-0004-02MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 7 | |||
| 24 | Replace sealing rings (8, 9) of the fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6). | ||
| 25 | Replace sealing rings (10) of the fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6). | AR07.03-P-0004-01MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 3 | |||
| 26 | Install fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6) in the rear rail (2) and fasten with hold-down tools (7b). | When reusing, insert the fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6) into the cylinders in which they were previously installed. Engine damage will occur otherwise. |
|
| 27 | Install rear rail (2) with fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6). | ||
| 28 | Tighten screws (6b). | *BA07.52-P-1001-01G | |
| 29 | Install high-pressure line (3). | Do not bend or kink high-pressure line (3). Leaks can occur otherwise. |
|
| *BA07.03-P-1001-01MRT | |||
| Fig 2 | |||
| Fig 4 | |||
| 30 | Mount high-pressure line (4) to rear rail (2). | AR07.03-P-1003MSC | |
| 31 | Tighten screw (5). | *BA07.03-P-1004-01MRT | |
| 32 | Install engine wiring harness on rear rail (2). | ||
| 33 | Connect and lock electrical connectors of the fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6). | ||
| 34 | Install rear noise insulation. | ||
| 35 | Install oil separator. | AR01.20-P-9750MSC | |
| 36 | Install engine air intake duct downstream of air filter. | AR09.10-P-8130MSC | |
| 37 | Install air filter housing. | AR09.10-P-1150MSC | |
| 38 | Install upper service flap. | AR01.10-P-2405-02MSC | |
| *BA82.30-P-1001-01R | |||
| *BA00.10-P-1002-04A | |||
| 39 | Connect ground line to battery. | AR01.20-P-9750MSC | |
| 40 | Store injector injection quantity adjustment coding in ME-SFI [ME] control unit. | When replacing the fuel injectors for cylinders 4 to 6 (Y76/4 to Y76/6). | |
| AD00.00-P-2000-06ME | |||
| Check | |||
| 41 | Check fuel high-pressure circuit for leak tightness. | ||
| AD00.00-P-2000-06ME | |||
| AR07.03-P-1010-04MM | |||
| 42 | Carry out engine test run and check engine for proper operation and leak tightness. | ||
| 43 | Install upper engine cover. | AR01.10-P-2405MSC |
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 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 |
WINDSHIELD WIPER
| Number | Designation | Model 167 | |
|---|---|---|---|
| BA82.30-P-1001-01R | Nut to wiper arm on front windshield wiper system | Nm | 30 |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |