Remove/install rail with fuel injectors for cylinders 4, 5, 6

AR07.03-P-1054MRT

Remove/install rail with fuel injectors for cylinders 4, 5, 6

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

2

Rear rail

3

High pressure pipe

4

High pressure pipe

5

Screw

6b

Bolts

1

Front rail

2

Rear rail

3

High pressure pipe

7b

Hold-down tool

8

Sealing ring

9

Sealing ring

10

Sealing ring

Y76/4

Cylinder 4 fuel injector

Y76/5

Cylinder 5 fuel injector

Y76/6

Cylinder 6 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 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

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

AH00.00-P-0015-01CW



Remove

1

Disconnect ground line from battery.

AR54.10-P-0003LF

2

Remove air filter housing.

AR09.10-P-1150MRT

3

Remove engine air intake duct downstream of air filter.

AR09.10-P-8130MRT

4

Remove the oil separator.

AR01.20-P-9750MRT

5

Remove rear noise insulation.

6

Clean environment of front rail (1), rear rail (2) and high-pressure lines (3, 4).

Assembly cleaner

*BR00.45-Z-1028-04A

7

Remove fuel pressure via the service connection.

AR07.03-P-1460-01MUB

 Cap on service connection

*BA07.03-P-1009-01MRT

 Pressure hose

*119589046300

8

Release fuel pressure in the fuel high-pressure circuit.

AR07.03-P-1460-02MM

9

Release and disconnect electrical connectors of fuel injectors (Y76/4, Y76/5, Y76/6).

10

Remove engine wiring harness from rear rail (2).

11

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

 Box wrench bit

*000589690300

 Record plug

*129589009100

12

Remove screw (5).

13

Remove high-pressure line (4) from rear rail (2).

AR07.03-P-1003MRT

14

Mark fuel injectors (Y76/4, Y76/5, Y76/6) relative to corresponding cylinder.


Where fuel injectors (Y76/4, Y76/5, Y76/6) are reused, insert in cylinders in which these were previously installed.
Engine damage will occur otherwise.

15

Remove screws (6b).

16

Remove hold-down tools (7b).

17

Remove rear rail (2) and seal openings with suitable stop plugs.

 Record plug

*129589009100

18

Remove fuel injectors (Y76/4, Y76/5, Y76/6) and seal injector well bores with suitable stop plugs.

AR07.03-P-0004-03MM

 Engine oil that leaks out during fuel injector (Y76/4, Y76/5, Y76/6) disassembly is unproblematic. Reuse fuel injectors (Y76/4, Y76/5, Y76/6).

 Plug

*270589039100

 Puller

*278589003300



Check

19

Check high-pressure lines (3, 4) and replace if necessary.

AR07.03-P-1010-03MRT

Assembly cleaner

*BR00.45-Z-1028-04A

20

Check fuel injectors (Y76/4, Y76/5, Y76/6) for external damage and replace if necessary.



Clean

21

Clean fuel connections for fuel injectors (Y76/4, Y76/5, Y76/6).


For cleaning the fuel connections, hold downwards.
Fuel injectors (Y76/4, Y76/5, Y76/6) will otherwise fail.

Assembly cleaner

*BR00.45-Z-1028-04A



Install

22

Replace sealing packages of rear rail (2).

AR07.03-P-0004-02MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Drift

*278589011500

23

Replace sealing rings (8, 9) of fuel injectors (Y76/4, Y76/5, Y76/6).

24

Replace sealing rings (10) of fuel injectors (Y76/4, Y76/5, Y76/6).

AR07.03-P-0004-01MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Assembly tool

*272589004300

25

Install fuel injectors (Y76/4, Y76/5, Y76/6) in rear rail (2) and secure with hold-down tools (7b).


Where fuel injectors (Y76/4, Y76/5, Y76/6) are reused, insert in cylinders in which these were previously installed.
Engine damage will occur otherwise.

 Replace hold-down tools (7b).

26

Install rear rail (2) with fuel injectors (Y76/4, Y76/5, Y76/6).

27

Tighten screws (6b).

 Screw/bolt, fuel distributor to cylinder head cover

*BA07.52-P-1001-01G

28

Install high-pressure line (3).


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

29

Install high-pressure line (4) at rear rail (2).

AR07.03-P-1003MRT

30

Tighten screw (5).

 Bolt, holder for high-pressure line to camshaft housing/cylinder head

*BA07.03-P-1004-01MRT

31

Install engine wiring harness at rear rail (2).

32

Connect and lock electrical connectors of fuel injectors (Y76/4, Y76/5, Y76/6).

33

Install rear noise insulation.

34

Install oil separator.

AR01.20-P-9750MRT

35

Install engine air intake duct downstream of air filter.

AR09.10-P-8130MRT

36

Install air filter housing.

AR09.10-P-1150MRT

 Only install upper engine cover after the leak test.

37

Connect ground line to battery.

AR54.10-P-0003LF

38

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

When fuel injectors (Y76/4, Y76/5, Y76/6) are replaced.



AD00.00-P-2000-04B



Check

39

Check fuel high-pressure circuit for leak tightness.

AR07.03-P-1010-04MM



AD00.00-P-2000-04B

40

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

41

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-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

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01