Remove/install rail with fuel injectors for cylinders 1, 2, 3

AR07.03-P-1053MRT

Remove/install rail with fuel injectors for cylinders 1, 2, 3

06.03.2020

Engine

256.9 in model 222

Modification notes

11.12.2019

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

BA07.03-P-1001-01MRT

1

Front rail

3

High pressure pipe

6a

Bolts

B4/25

Fuel pressure and temperature sensor

1

Front rail

3

High pressure pipe

7a

Hold-down tool

8

Sealing ring

9

Sealing ring

10

Sealing ring

Y76/1

Cylinder 1 fuel injector

Y76/2

Cylinder 2 fuel injector

Y76/3

Cylinder 3 fuel injector

 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

 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

 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

 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 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-0003LF

2

Remove air filter housing.

AR09.10-P-1150MRT

3

Remove front noise insulation.

4

Clean environment of front rail (1) and high-pressure line (3).

Assembly cleaner

*BR00.45-Z-1028-04A

5

Remove fuel pressure via the service connection.

AR07.03-P-1460-01MUB

 Cap on service connection

*BA07.03-P-1009-01MRT

 Pressure hose

*119589046300

6

Release fuel pressure in the fuel high-pressure circuit.

AR07.03-P-1460-02MM

7

Release and disconnect electrical connection at fuel pressure and temperature sensor (B4/25).

8

Release and disconnect electrical connectors of fuel injectors (Y76/1, Y76/2, Y76/3).

9

Remove engine wiring harness from front rail (1).

10

Remove high-pressure line (3) and seal openings with suitable stop plugs.

 Box wrench bit

*000589690300

 Record plug

*129589009100

11

Mark fuel injectors (Y76/1, Y76/2, Y76/3) relative to corresponding cylinder.


Where fuel injectors (Y76/1, Y76/2, Y76/3) are reused, insert in cylinders in which these were previously installed.
Engine damage will occur otherwise.

12

Remove screws (6a).

13

Remove hold-down tools (7a).

14

Remove front rail (1) and seal openings with suitable stop plugs.

 Record plug

*129589009100

15

Remove fuel injectors (Y76/1, Y76/2, Y76/3) and seal injector well bores with suitable stop plugs.

AR07.03-P-0004-03MM

 Engine oil that leaks out during fuel injector (Y76/1, Y76/2, Y76/3) disassembly is unproblematic. Reuse fuel injectors (Y76/1, Y76/2, Y76/3).

 Plug

*270589039100

 Puller

*278589003300

16

Remove fuel pressure and temperature sensor (B4/25).

When replacing front rail (1).

AR07.04-P-0091MRT



Check

17

Check high-pressure line (3) and replace if necessary.

AR07.03-P-1010-03MRT

Assembly cleaner

*BR00.45-Z-1028-04A

18

Check fuel injectors (Y76/1, Y76/2, Y76/3) for external damage and replace if necessary.



Clean

19

Clean fuel connections at fuel injectors (Y76/1, Y76/2, Y76/3).


For cleaning the fuel connections, hold downwards.
Fuel injectors (Y76/1, Y76/2, Y76/3) will otherwise fail.

Assembly cleaner

*BR00.45-Z-1028-04A



Install

20

Replace sealing packages of front rail (1).

AR07.03-P-0004-02MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Drift

*278589011500

21

Replace sealing rings (8, 9) of fuel injectors (Y76/1, Y76/2, Y76/3).

22

Replace sealing rings (10) of fuel injectors (Y76/1, Y76/2, Y76/3).

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) in front rail (1) and secure with hold-down tools (7a).


Where fuel injectors (Y76/1, Y76/2, Y76/3) are reused, insert in cylinders in which these were previously installed.
Engine damage will occur otherwise.

 Replace hold-down tools (7a).

24

Install front rail (1) with fuel injectors (Y76/1, Y76/2, Y76/3).

25

Tighten screws (6a).

 Screw/bolt, fuel distributor to cylinder head cover

*BA07.52-P-1001-01G

26

Install high-pressure line (3).

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

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

AH00.00-P-0015-01CW


Do not kink or bend 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

*129589009100

 Box wrench bit

*000589690300

27

Install fuel pressure and temperature sensor (B4/25).

When replacing front rail (1).

AR07.04-P-0091MRT

28

Connect and lock electrical connector of fuel pressure and temperature sensor (B4/25).

29

Install engine wiring harness in front rail (1).

30

Connect and lock electrical connectors of fuel injectors (Y76/1, Y76/2, Y76/3).

31

Install front noise insulation.

32

Install air filter housing.

AR09.10-P-1150MRT

 Only install upper engine cover after the leak test.

33

Connect ground line to battery.

AR54.10-P-0003LF

34

Store injector quantity compensation coding in ME-SFI [ME] control unit.

When replacing fuel injectors (Y76/1, Y76/2, Y76/3).



AD00.00-P-2000-04B



Check

35

Check high-pressure fuel circuit for leak tightness.

AR07.03-P-1010-04MM



AD00.00-P-2000-04B

36

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

37

Install upper engine cover.

AR01.10-P-2405MRT

 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-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

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01