Remove/install rail with fuel injectors · ar0703p1052mrh · Mercedes-Benz WIS

AR07.03-P-1052MRH

Remove/install rail with fuel injectors

04.05.2020

Engine

264 in model 213, 238, 257

Modification notes

05.12.2019

Document completely revised.

P07.03-2416-08

Shown on model 238 with engine 264

1	Shielding	Y76/1	Cylinder 1 fuel injector
2	High pressure pipe	Y76/2	Cylinder 2 fuel injector
3	Rail	Y76/3	Cylinder 3 fuel injector
4	Hold-down tool	Y76/4	Cylinder 4 fuel injector
B4/25	Fuel pressure and temperature sensor

Shown on model 238 with engine 264

3	Rail
4	Hold-down tool
5	Sealing ring
6	Sealing ring
7	Sealing ring

P07.03-2417-06

 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 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 coolant		AH20.00-N-2080-01A
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	Relieve fuel pressure using diagnostic system.
		Engine 264 in model 213	AD00.00-P-2000-04B
		Engine 264 in model 238	AD00.00-P-2000-06LWO
		Engine 264 in model 257	AD00.00-P-2000-06FR
		 To do so, select following menu items: ME-SFI [ME] control unit  Actuation  Actuate the fuel pump .
2	Remove ground line of battery.	Engine 264 in model 213	AR54.10-P-0003LW
		Engine 264 in model 238	AR54.10-P-0003LWO
		Engine 264 in model 257	AR54.10-P-0003FR
3	Remove rear engine cover.		AR01.10-P-2408MRH
 Warning	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
4	Remove engine wiring harness.		AR15.18-P-1000-04MRH
		 Do not kink or subject lines to tension. Otherwise damage will occur.
		 Record plug	*129589009100
		 Hose clamp pliers	*454589003700
5	Remove shielding (1).	Tightening procedure for high-pressure pump shielding	AR07.02-P-0815-01MRH
		 Loosen the shielding (1) in the direction in contrary to the tightening procedure.
6	Remove soundproofing for high-pressure pump.
7	Clean area around high-pressure pump, high-pressure line (2) and rail (3).	Assembly cleaner	*BR00.45-Z-1028-04A
8	Release fuel pressure in the fuel high-pressure circuit.		AR07.03-P-1460-02MM
9	Remove high-pressure line (2) and seal connections with suitable stop plugs.	 Do not kink or bend high-pressure line (2). Leaks can occur otherwise.
		 Box wrench bit	*000589800300
		 Record plug	*129589009100
10	Remove the intake camshaft valve lift changeover actuator (Y49/8).		AR05.20-P-6560MRH
11	Mark fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) to indicate corresponding cylinders.	When reusing the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).
		 When reusing the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4), insert them into the cylinders in which they were previously installed. Engine damage will occur otherwise.
12	Remove hold-down tools (4).
13	Unscrew screws of rail (3) in reverse order of tightening procedure.	Rail tightening procedure	AR07.03-P-1010-06MRH
14	Take out rail (3) and seal connections with suitable stop plugs.	 Ensure utmost cleanliness. Otherwise, leaks and malfunctions occur.
		 Record plug	*129589009100
15	Pull fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) out of cylinder head and seal injector shaft bores with suitable stop plugs.		AR07.03-P-0004-03MM
		 Plug	*270589039100
		 Puller	*278589003300
16	Remove fuel pressure and temperature sensor (B4/25).	When installing new rail(3).
			AR07.04-P-0093MRH
	Check
17	Check fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) for external damage and replace if necessary.	When reusing the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).
		 If new fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) are to be installed, they must be installed immediately after removing the transport protection caps. Leaks can occur otherwise.
18	Check the high-pressure line (2).		AR07.03-P-1010-03MM
		Assembly cleaner	*BR00.45-Z-1028-04A
	Clean
19	Clean fuel connections on fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).	When reusing the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).
		 For cleaning the fuel connections, hold downwards. Otherwise the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) may fail.
		Assembly cleaner	*BR00.45-Z-1028-04A
	Install
20	Replace sealing package of rail (3).		AR07.03-P-0004-02MM
		 Drift	*278589011500
21	Install new sealing rings (5, 6) for fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).	When reusing the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).
22	Replace sealing rings (7) of fuel injectors (Y76/1, Y76/2, Y763,Y76/4).	When reusing the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).
			AR07.03-P-0004-01MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		 Assembly tool	*272589004300
23	Install fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) into rail (3) and fasten with new hold-down tools (4).	 When reusing the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4), insert them into the cylinders in which they were previously installed. Engine damage will occur otherwise.
24	Remove stop plugs of injector well bores.	 Plug	*270589039100
25	Install rail (3) with fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).
26	Tighten screws of rail (3).	Rail tightening procedure	AR07.03-P-1010-06MRH
		 Screw/bolt, fuel distributor to cylinder head cover	*BA07.52-P-1001-01K
27	Install fuel pressure and temperature sensor (B4/25).	When installing new rail(3).
			AR07.04-P-0093MRH
28	Install high-pressure line (2).	 Do not kink or bend high-pressure line (2). Leaks can occur otherwise.
		 Union nut, fuel line to high-pressure pump/fuel distributor	*BA07.03-P-1001-01I
		 Box wrench bit	*000589800300
29	Install the intake camshaft valve lift changeover actuator (Y49/8).		AR05.20-P-6560MRH
30	Install soundproofing for high-pressure pump.
31	Install shielding (1).	Tightening procedure for high-pressure pump shielding	AR07.02-P-0815-01MRH
		 Bolt for high-pressure pump shielding	*BA07.02-P-1002-02A
 Warning	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
32	Install engine wiring harness.		AR15.18-P-1000-04MRH
	Notes on coolant level		AH20.00-P-1142-01CW
		 Cooling system	*BF20.00-P-1001-06D
		 M61	*BA00.10-P-1002-04A
		 Record plug	*129589009100
		 Hose clamp pliers	*454589003700
33	Check engine cooling system for leak tightness.		AR20.00-P-1011OLC
34	Connect ground line to battery.	Engine 264 in model 213	AR54.10-P-0003LW
		Engine 264 in model 238	AR54.10-P-0003LWO
		Engine 264 in model 257	AR54.10-P-0003FR
35	Read out fault memory with vehicle diagnosis system and delete if necessary.
		Engine 264 in model 213	AD00.00-P-2000-04B
		Engine 264 in model 238	AD00.00-P-2000-06LWO
		Engine 264 in model 257	AD00.00-P-2000-06FR
36	Store injector quantity compensation (IMA) coding in motor control module (MCM).	When you install new fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).
		Engine 264 in model 213	AD00.00-P-2000-04B
		Engine 264 in model 238	AD00.00-P-2000-06LWO
		Engine 264 in model 257	AD00.00-P-2000-06FR
37	Check the fuel high-pressure circuit.		AR07.03-P-1010-04MM
		Engine 264 in model 213	AD00.00-P-2000-04B
		Engine 264 in model 238	AD00.00-P-2000-06LWO
		Engine 264 in model 257	AD00.00-P-2000-06FR
38	Perform engine test run and check engine for proper operation and leak tightness.
39	Remove the engine cover at the rear.		AR01.10-P-2408MRH

 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

 Fuel system high pressure pump

Number	Designation		Engine 264
BA07.02-P-1002-02A	Bolt for high-pressure pump shielding	Nm	20

 Injection nozzles, injection valves, lines

Number	Designation			Engine 264
BA07.03-P-1001-01I	Union nut, fuel line to high-pressure pump/fuel distributor	Stage 1	Nm	15
		Stage 2	°	75
		Stage 3	°	25

 Fuel distributor

Number	Designation		Engine 264
BA07.52-P-1001-01K	Screw/bolt, fuel distributor to cylinder head cover	Nm	8

 Cooling system

Number	Designation				Engine 264 in model 213	Engine 264 in model 238.377/378/380/383/387/477/478/480/483/487
BF20.00-P-1001-06D	Cooling system	Workshop replacement amount	Main circuit	Liter	11,0	9,0
			Low-temperature circuit	Liter	-	-
		Antifreeze/water	Down to -37 °C	%	50/50	50/50
			-38 °C and below	%	50/45	50/45
			Specifications for Operating Fluids, sheet		BB00.40-P-0310-01A	BB00.40-P-0310-01A
			Specifications for Operating Fluids, sheet		BB00.40-P-0325-06A	BB00.40-P-0325-06A
			Specifications for Operating Fluids, sheet		BB00.40-P-0326-06A	BB00.40-P-0326-06A

 Cooling system

Number	Designation				Engine 264 in model 238.385/386/485	Engine 264 in model 257.348
BF20.00-P-1001-06D	Cooling system	Workshop replacement amount	Main circuit	Liter	10,0	14,0
			Low-temperature circuit	Liter	-	-
		Antifreeze/water	Down to -37 °C	%	50/50	50/50
			-38 °C and below	%	50/45	50/45
			Specifications for Operating Fluids, sheet		BB00.40-P-0310-01A	BB00.40-P-0310-01A
			Specifications for Operating Fluids, sheet		BB00.40-P-0325-06A	BB00.40-P-0325-06A
			Specifications for Operating Fluids, sheet		BB00.40-P-0326-06A	BB00.40-P-0326-06A

 Cooling system

Number	Designation				Engine 264 in model 257 (except 257.348)
BF20.00-P-1001-06D	Cooling system	Workshop replacement amount	Main circuit	Liter	9,0
			Low-temperature circuit	Liter	4,0
		Antifreeze/water	Down to -37 °C	%	50/50
			-38 °C and below	%	50/45
			Specifications for Operating Fluids, sheet		BB00.40-P-0310-01A
			Specifications for Operating Fluids, sheet		BB00.40-P-0325-06A
			Specifications for Operating Fluids, sheet		BB00.40-P-0326-06A

454 589 00 37 00

Hose clamp pliers

270 589 03 91 00

Plug

129 589 00 91 00

Record plug

272 589 00 43 00

Assembly tool

000 589 80 03 00

Box wrench bit

278 589 00 33 00

Puller

278 589 01 15 00

Drift

Repair materials

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

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