Remove/install rail with fuel injectors

AR07.03-P-1052MRM

Remove/install rail with fuel injectors

06.03.2020

Engine

274.9 in model 167

20

Cover

21

Partition wall

22

Electrical wiring harness

23

Screw

1

Hold-down tool

2

Sealing ring

3

Sealing ring

4

Sealing ring

8

Rail

Y76/1

Cylinder 1 fuel injector

Y76/2

Cylinder 2 fuel injector

Y76/3

Cylinder 3 fuel injector

Y76/4

Cylinder 4 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 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 cover for air/water duct.

AR83.10-P-1411ME

2

Unclip cover (20) (arrows) and remove.

3

Unclip line of the inerting system from the partition (21).

Engine 274.9 in model 167
with code 2U8 (Alternative refrigerant)

4

Unclip electrical wiring harness (22) from the partition (21).

5

Remove screws (23) and remove the partition (21) upward.

6

Remove engine compartment lining at rear.

AR61.20-P-1105ME

7

Remove fuel pressure.

AR07.03-P-1460-01MR

 Dust cap at service connection

*BA07.03-P-1003-01F

 Pressure hose

*119589046300

8

Disconnect ground line from battery.

AR54.10-P-0003ME

9

Remove upper engine cover.



AP01.10-P-2405-01O

10

Remove engine wiring harness.

AR15.18-P-1000-04MRM

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

11

Loosen screws of the shielding (5) contrary to the tightening procedure and remove shielding (5).

Tightening procedure

AR07.02-P-0815-01MR

12

Remove soundproofing of the high-pressure pump.

13

Clean area around the high-pressure pump, high-pressure line (7), and rail (8).


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

14

Release fuel pressure in the fuel high-pressure circuit.

AR07.03-P-1460-02MM

15

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

16

Mark fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) relative to the corresponding cylinder.

If the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) are reused.


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.

17

Remove hold-down tools (1).

18

Remove screws (6) of the rail (8) contrary to the tightening procedure.

Tightening procedure

AR07.03-P-1010-06MR

19

Detach rail (8) from the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) and seal connections with suitable stop plugs.

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

 Record plug

*129589009100

20

Remove fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) from cylinder head and seal injector well bores with suitable stop plugs.

AR07.03-P-0004-03MM

 Plug

*270589039100

 Puller

*278589003300

21

Remove fuel pressure and temperature sensor.

If a new rail (8) is installed.

AR07.04-P-0093MRM



Check

22

Check fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) for external damage and replace if necessary.

If the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) are reused.


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.

23

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

AR07.03-P-1010-03MM

Assembly cleaner

*BR00.45-Z-1028-04A



Clean

24

Clean fuel connections on fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).

If the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) are reused.


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

25

Install new sealing packages of the rail (8).

AR07.03-P-0004-02MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Drift

*278589011500

26

Install new sealing rings (2, 3) of the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).

If the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) are reused.

27

Install new sealing rings (4) of the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).

If the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) are reused.

AR07.03-P-0004-01MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Assembly tool

*272589004300

28

Install fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) in the rail (8) and secure with hold-down tools (1).


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.

 Install new hold-down tools (1).

29

Remove stop plugs of injector well bores.

30

Install rail (8) with fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).

31

Screw in screws (6) of the rail (8).

Tightening procedure

AR07.03-P-1010-06MR

 Screw/bolt, fuel distributor to cylinder head cover

*BA07.52-P-1001-01H

32

Install fuel pressure and temperature sensor.

If a new rail (8) is installed.

AR07.04-P-0093MRM

33

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

34

Install soundproofing of the high-pressure pump.

35

Install shielding (5).

Tightening procedure

AR07.02-P-0815-01MR

 Bolt for high-pressure pump shielding

*BA07.02-P-1004-01D

36

Install engine wiring harness.

AR15.18-P-1000-04MRM

 Screw, engine cable duct to cylinder head cover/charge-air distributor/oil separator/high-pressure pump shielding

*BA01.20-P-1010-01R

37

Connect ground line of battery .

AR54.10-P-0003ME

38

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



AD00.00-P-2000-06ME

39

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

When installing new fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).



AD00.00-P-2000-06ME



Check

40

Check high-pressure fuel circuit.

AR07.03-P-1010-04MM



AD00.00-P-2000-06ME

41

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

42

Install upper engine cover.



AP01.10-P-2405-01O

43

Install rear engine compartment lining.

AR61.20-P-1105ME

44

Insert partition (21) and screw in screws (23).

 Ensure that the partition (21) is seated correctly in the lower part of the partition.

 Screw, upper engine compartment partition to lower engine compartment partition

*BA62.30-P-1012-02I

45

Clip electrical wiring harness (22) onto the partition (21).

46

Clip line of the inerting system onto the partition (21).

Engine 274.9 in model 167
with code 2U8 (Alternative refrigerant)

47

Clip in cover (20) (arrows).

48

Install cover for air/water duct.

AR83.10-P-1411ME

 Crankcase ventilation system, cylinder head cover, camshaft housing

Number

Designation

Engine 274

BA01.20-P-1010-01R

Screw, engine cable duct to cylinder head cover/charge-air distributor/oil separator/high-pressure pump shielding

Nm

8

 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

 Frond end with reinforcement

Number

Designation

Model 167

BA62.30-P-1012-02I

Screw, upper engine compartment partition to lower engine compartment partition

4

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01