Remove/install fuel injectors

AR07.03-P-0004MT

Remove/install fuel injectors

06.03.2020

Engine

133 in model 117, 156, 176

Engine

270 in model 117, 156, 176, 242, 246.2

Modification notes

16.01.2017

 Stop plug new, added.

Operation step 4

270 589 03 91 00

Shown on model 246.242

2

Sealing ring

3

Sealing ring

4

Sealing ring

Y76

Fuel injectors

 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

 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

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

 

Remove/install

1

Disconnect battery ground line

AR54.10-P-0003NKB

2

Remove the rail

AR07.03-P-1010MT

 Installation: Only install upper engine cover after the leak test.

3

Mark fuel injectors (Y76) relative to the respective cylinder


When reusing the fuel injectors (Y76) they must be inserted into the cylinder in which it was previously installed.
Engine damage will occur otherwise.

4

Pull fuel injectors (Y76) out of cylinder head and close injector shaft bore with grommet

AR07.03-P-0004-03MM

 Installation:
If the fuel injectors (Y76) are replaced, these must be installed immediately after removal of the transport protective caps.
Leaks can occur otherwise.

 Engine oil which escapes for disassembly of the fuel injectors (Y76), is safe and the fuel injectors (Y76) can be reused.

 Installation: The fuel injectors (Y76) must be installed together with the rail.

 Plug

*270589039100

 Puller

*278589003300

5

Remove spark plugs

Engine 270 in model 242
with code 924 (Bivalent natural gas drive)



AP15.10-P-1580NK



Check

6

Check fuel injectors (Y76) for external damage

For damage to the fuel injectors (Y76)



Replace fuel injectors (Y76).



Clean

7

Clean fuel connections on fuel injectors (Y76)


During cleaning the fuel connections must be held downwards.
Otherwise failure of the fuel injectors (Y76).

Assembly cleaner

*BR00.45-Z-1028-04A

8

Clean bores of the injector tips in cylinder head from combustion residues and suction out combustion residues

Engine 270 in model 242
with code 924 (Bivalent natural gas drive)


Clean bores of injector tips in cylinder head with  cylinder brush.
Otherwise the seals of fuel injectors (Y76) will be damaged for installation.


It is essential to maintain rotational speed and cleaning time.
Stock removal on the cylinder head will occur otherwise and therefore to damage which could result in exchange of the cylinder head.

 Remove connecting hose from  adapter, connect to vacuum cleaner and introduce connecting hose into spark plug bore, in order to suction off the cleaning dust parallel to the cleaning process.

  Insert cylinder brush in cordless screwdriver and clean with a rotational speed of <500 rpm for each bore for about 4 s and then blow up the injector shaft with compressed air.

 Adapter

*270589006800

 Cylinder brush

*270589016800

9

Replace sealing rings (2, 4) on fuel injectors (Y76)

10

Replace sealing rings (3) for fuel injectors (Y76)

AR07.03-P-0004-01MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Assembly tool

*272589004300

11

Install in the reverse order

12

Store injector quantity compensation (IMA) coding in engine management (MCM) control unit

For installation of new fuel injectors (Y76).



AD00.00-P-2000-04A

13

Read out and erase fault memory



AD00.00-P-2000-04A

 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

14

Carry out engine test run, checking the engine for proper operation and leaktightness of the fuel system

15

Install upper engine cover

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01