Remove/install fuel distributor with fuel injectors

AR07.03-P-1055MFC

Remove/install fuel distributor with fuel injectors

06.03.2020

Engine

260 in model 118, 177, 247

Modification notes

04.11.2019

Document completely revised.

Shown on engine 260 with code M016 (performance-enhanced engine)

1

Fuel distributor

5

Noise insulation

2

Adapter

6

High pressure pipe

3

Vent line

Y49/8

Intake camshaft valve lift switching actuator

4

Shaped hose

1

Fuel distributor

9

Bolts

Y76/3

Cylinder 3 fuel injector

7

Sealing package

Y76/1

Cylinder 1 fuel injector

Y76/4

Cylinder 4 fuel injector

8

Retaining spring

Y76/2

Cylinder 2 fuel injector

10

Seal

11

Sealing ring

12

Sealing ring

Y76/1

Cylinder 1 fuel injector

Y76/2

Cylinder 2 fuel injector

Y76/3

Cylinder 3 fuel injector

Y76/4

Cylinder 4 fuel injector

 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

 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

 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

 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

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

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

AH00.00-P-0020-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

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.

AR07.00-P-0003-01MFA



AD00.00-P-2000-06MFA

2

Relieve fuel residue pressure.

AR07.03-P-1460-02MM

3

Remove ground line from the on-board electrical system battery (G1).

AR54.10-P-0003MFA

4

Remove upper engine cover.



AP01.10-P-2405-01C

5

Remove adapter (2) from the engine air intake duct, place to one side with connected lines, and seal openings with suitable stop plugs.

 Record plug

*129589009100

 Set of plugs

*199589009800

6

Remove bleed line (3) from the engine air intake duct, unclip from the filler neck, place to one side, and seal openings with suitable stop plugs.

 Record plug

*129589009100

7

Remove molded hose (4) and seal openings with protective covers.

Engine 260
with code M016 (Uprated engine)

 Hose clamp pliers

*454589003700

 Set of protective caps

*001589029100

 Set of protective caps

*001589009100

8

Remove noise insulation (5) of the high-pressure pump.

9

Detach the engine wiring harness on the cylinder head cover.

AR15.18-P-1000-04MFC

 Do not disconnect the electrical connections on the intake camshaft solenoid (Y49/1) or exhaust camshaft solenoid (Y49/2).

 Dismantling tool

*000589956300

10

Clean area around the high-pressure pump, high-pressure line (6), and the fuel distributor (1).


Thoroughly clean area around the fuel high pressure circuit so that no dirt can find its way into the fuel injection system.
Failure of the fuel injection system can occur otherwise.

Assembly cleaner

*BR00.45-Z-1028-04A

11

Remove high-pressure line (6) and seal openings with suitable stop plugs.


Do not kink, bend, or drop high-pressure line (6).
Otherwise damage and leaks can occur.

 Record plug

*129589009100

 Box wrench bit

*000589680300

12

Remove the intake camshaft valve lift changeover actuator (Y49/8).

AR05.20-P-6500MFC

13

Remove screws(9) in reverse order of tightening procedure.

Fuel distributor tightening procedure

AR07.03-P-1030-01MFC

14

Remove retaining springs (8).

15

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

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

16

Remove fuel distributor (1) from the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) and seal openings on the fuel distributor  (1) with suitable stop plugs.

 Record plug

*129589009100

17

Remove fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) and seal injector shaft bores with the stop plugs.

AR07.03-P-0004-03MM

 Any engine oil that escapes when removing the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) is inconsequential.

 Puller

*278589003300

 Plug

*270589039100

18

Clean fuel connections of the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) and seal exposed openings with suitable stop plugs.


For cleaning the fuel connections, hold downwards.
Otherwise, dirt will get into the openings.

Assembly cleaner

*BR00.45-Z-1028-04A

 Record plug

*129589009100



Check

19

Check high-pressure line (6).

AR07.03-P-1010-03MM

Assembly cleaner

*BR00.45-Z-1028-04A

20

Check fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) for damage.

If there are problems,



replace corresponding fuel injector (Y76/1, Y76/2, Y76/3, Y76/4).



Install

21

Install new sealing packages (7) of the fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4).

AR07.03-P-0004-02MM

Assembly cleaner

*BR00.45-Z-1028-04A

 Drift

*278589011500

22

Install new seal (10) and sealing rings (11, 12) 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

23

Install fuel injectors (Y76/1, Y76/2,  Y76/3, Y76/4) into the fuel distributor (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.


If new fuel injectors (Y76/1, Y76/2,  Y76/3, Y76/4) are installed, they must be installed immediately after removing the transport protection caps.
Leaks can occur otherwise.

 replace the retaining springs (8).

If one or more fuel injectors (Y76/1, Y76/2,  Y76/3, Y76/4) were replaced,



note down the injector quantity compensation coding according to the cylinder.

24

Install fuel distributor (1) with the fuel injectors (Y76/1, Y76/2,  Y76/3, Y76/4).

25

Screw in screws (9) as per the tightening procedure.

Fuel distributor tightening procedure

AR07.03-P-1030-01MFC

 Screw/bolt, fuel distributor to cylinder head cover

*BA07.52-P-1001-01H

26

Install the high-pressure line (6).

AR07.03-P-1010-02MT


Do not kink, bend or drop the high-pressure line (6).
Leaks or damage can occur otherwise.

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

*BA07.03-P-1001-01I

 Box wrench bit

*000589680300

27

Install the intake camshaft valve lift changeover actuator (Y49/8).

AR05.20-P-6500MFC

28

Connect the engine wiring harness for the cylinder head cover and route it along the original fastening points.

AR15.18-P-1000-04MFC

 Engine ground point

*BA00.19-P-1002-02E

29

Install noise insulation (5) of the high-pressure pump.

30

Install molded hose (4).

Engine 260
with code M016 (Uprated engine)

 Hose clamp pliers

*454589003700

31

Attach bleed line (3) to the engine air intake duct and clip into the filler neck.

32

Attach adapter (2) to the engine air intake duct.

 Replace seals.

 Bolt, bleed line for oil separator to clean air line

*BA01.20-P-1008-03C

33

Attach ground line of the on-board electrical system battery (G1).

AR54.10-P-0003MFA

Initial startup

34

Commission the ME control unit (N3/10).

If one or more fuel injectors (Y76/1, Y76/2,  Y76/3, Y76/4) were replaced.



AD00.00-P-2000-06MFA


Store injector quantity compensation coding in the ME-SFI control unit (N3/10).
Engine running problems could otherwise occur.



Check

35

Check the fuel high-pressure circuit.



AD00.00-P-2000-06MFA

AR07.03-P-1010-04MM

36

Read out and delete fault memory.



AD00.00-P-2000-06MFA

37

Perform engine test run and while doing so, check engine for proper operation and fuel injection system in terms of leak tightness.

AR07.03-P-1010-04MM

38

Install upper engine cover.



AP01.10-P-2405-01C

 Ground points

Number

Designation

Model 118

Model 177

BA00.19-P-1002-02E

Engine ground point

W2/8

M5

Nm

9

9

 Ground points

Number

Designation

Model 247

BA00.19-P-1002-02E

Engine ground point

W2/8

M5

Nm

9

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 260

BA01.20-P-1008-03C

Bolt, bleed line for oil separator to clean air line

Nm

5

 Injection nozzles, injection valves, lines

Number

Designation

Engine 260

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 260

BA07.52-P-1001-01H

Screw/bolt, fuel distributor to cylinder head cover

Nm

8

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01