Remove/install rail with fuel injectors

AR07.03-P-1052MRD

Remove/install rail with fuel injectors

06.03.2020

Engine

274.9 in model 213

Engine

274.9 in model 238

Modification notes

21.11.2019

Document completely revised.

2

Sealing ring

3

Sealing ring

4

Sealing ring

Y76

Fuel injector

5

Shielding

6

Screws (x 8)

7

High pressure pipe

8

Rail

 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 contactwith 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

 Warning

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

 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

 Caution

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

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

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

Notes on safety-relevant components

AH00.00-Z-0019-01A



Remove

1

Remove center and rear sections of lower engine compartment lining.

AR61.20-P-1105LWE

2

Remove fuel pressure.

AR07.03-P-1460-01MR

 Dust cap at service connection

*BA07.03-P-1003-01F

 Pressure hose

*119589046300

3

Remove ground line of battery.

Engine 274.9 in model 238

AR54.10-P-0003LWO

Engine 274.9 in model 213

AR54.10-P-0003LW

4

Remove upper engine cover.

5

Remove soundproofing.

Engine 274.9 in model 213
Engine 274.9 in model 238

Engine 274.9 in model 213
except code 920 (Direct petrol injection with stratified charging)
Engine 274.9 in model 238
except code 920 (Direct petrol injection with stratified charging)

AR94.30-P-5410MRD

6

Remove engine wiring harness.

AR15.18-P-1000-04MRD


Do not kink lines, do not subject lines to tension.
Otherwise damage will occur.

7

Release shielding (5) in reverse order to the tightening procedure and remove.

Tightening procedure for high-pressure pump shielding

AR07.02-P-0815-01MR

8

Remove soundproofing of the high-pressure pump.

9

Clean area around high-pressure pump and high-pressure line (7).


No dirt should be allowed to find its way into the fuel injection system.
Failure of the fuel injection system can occur otherwise.

Assembly cleaner

*BR00.45-Z-1028-04A

10

Release fuel pressure in the fuel high-pressure circuit.

AR07.03-P-1460-02MM

11

Remove high-pressure line (7) and seal connections with suitable stop plugs.


Do not kink or bend high-pressure line (7).
Leaks can occur otherwise.

 Box wrench bit

*000589800300

 Record plug

*129589009100

12

Unscrew screws (6) in reverse order to tightening procedure.

Rail tightening procedure

AR07.03-P-1010-06MR

13

Remove hold-down tools between rail (8) and fuel injectors (Y76).

14

Mark fuel injectors (Y76) relative to the respective cylinder.


Where fuel injectors (Y76) are reused, insert these in cylinder in which they were previously installed.
Engine damage will occur otherwise.

15

Remove rail (8) from fuel injectors (Y76) and seal connections with suitable stop plugs.


Ensure utmost cleanliness.
Otherwise, leaks and malfunctions occur.

 Record plug

*129589009100

16

Remove fuel injectors (Y76) from cylinder head and seal injector well bores with suitable stop plugs.

AR07.03-P-0004-03MM

 Remove all fuel injectors (Y76), rail (8) may only be installed together with fuel injectors (Y76).

 Puller

*278589003300

 Plug

*270589039100



Check

17

Check fuel injectors (Y76) for external damage and replace if necessary.


If fuel injectors (Y76) are replaced, install these immediately after removal of transport protective caps.
Leaks can occur otherwise.

18

Check high-pressure line (7) for damage and replace if necessary.

AR07.03-P-1010-03MM

Assembly cleaner

*BR00.45-Z-1028-04A



Clean

19

Clean fuel connections at fuel injectors (Y76).


For cleaning the fuel connections, hold downwards.
Otherwise failure of the fuel injectors (Y76) can occur.

Assembly cleaner

*BR00.45-Z-1028-04A



Install

20

Replace sealing packages of fuel injectors (Y76) at rail (8).

AR07.03-P-0004-02MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Drift

*278589011500

21

Replace sealing rings (2, 4) of fuel injectors (Y76).

22

Replace sealing rings (3) of fuel injectors (Y76).

AR07.03-P-0004-01MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Assembly tool

*272589004300

23

Remove stop plugs, install fuel injectors (Y76) in rail (8) and secure with hold-down tools.


Where fuel injectors (Y76) are reused, insert these in cylinder in which they were previously installed.
Engine damage will occur otherwise.

 Replace hold-down tools.

 Record plug

*129589009100

24

Remove stop plugs and install rail (8) with fuel injectors (Y76).

 Plug

*270589039100

25

Screw in bolts (6).

Rail tightening procedure

AR07.03-P-1010-06MR

 Screw/bolt, fuel distributor to cylinder head cover

*BA07.52-P-1001-01H

26

Remove stop plugs and install high-pressure line (7).

AR07.03-P-1010-02MR


Do not kink or bend high-pressure line (7).
Leaks can occur otherwise.

 Union nut, fuel line to fuel distributor

*BA07.03-P-1001-01F

 Union nut, fuel line to high-pressure pump

*BA07.03-P-1002-01F

 Box wrench bit

*000589800300

 Record plug

*129589009100

27

Install soundproofing of the high-pressure pump.

28

Install shielding (5).

Tightening procedure for high-pressure pump shielding

AR07.02-P-0815-01MR

 Bolt for high-pressure pump shielding

*BA07.02-P-1004-01D

29

Install engine wiring harness.

AR15.18-P-1000-04MRD

 M61

*BA00.10-P-1002-04A

30

Install ground line of battery.

Engine 274.9 in model 238

AR54.10-P-0003LWO

Engine 274.9 in model 213

AR54.10-P-0003LW

31

Read out fault memory with vehicle diagnosis system and delete if necessary.



Engine 274.9 in model 213

AD00.00-P-2000-04B



Engine 274.9 in model 238

AD00.00-P-2000-06LWO

32

Store injector quantity compensation coding in motor control module (MCM).

For installation of new fuel injectors (Y76).



Engine 274.9 in model 213

AD00.00-P-2000-04B



Engine 274.9 in model 238

AD00.00-P-2000-06LWO



Check

33

Check fuel high-pressure circuit for leak tightness.



Engine 274.9 in model 213

AD00.00-P-2000-04B



Engine 274.9 in model 238

AD00.00-P-2000-06LWO

AR07.03-P-1010-04MM

34

Carry out engine test run and check engine for proper operation and leak tightness.

35

Install soundproofing.

Engine 274.9 in model 213
Engine 274.9 in model 238

Engine 274.9 in model 213
except code 920 (Direct petrol injection with stratified charging)
Engine 274.9 in model 238
except code 920 (Direct petrol injection with stratified charging)

AR94.30-P-5410MRD

36

Install center and rear lower engine compartment lining.

AR61.20-P-1105LWE

37

Install upper engine cover.

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 High pressure pump

Number

Designation

Engine 274

BA07.02-P-1004-01D

Bolt for high-pressure pump shielding

Nm

20

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274

BA07.03-P-1001-01F

Union nut, fuel line to fuel distributor

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274

BA07.03-P-1002-01F

Union nut, fuel line to high-pressure pump

Stage 1

Nm

15

Stage 2

°

75

Stage 3

°

25

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274

BA07.03-P-1003-01F

Dust cap at service connection

Plastic

Nm

2

Metal

Nm

15

 Fuel distributor

Number

Designation

Engine 274

BA07.52-P-1001-01H

Screw/bolt, fuel distributor to cylinder head cover

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01