Remove/Install Fuel Rail With Fuel Injectors - AR07.03-P-1052MRI
Engine 264 in Model 205, 253
MODIFICATION NOTES
| 21.11.2019 | Document completely revised. | ||
| 25.04.2021 | Cooling system | BF20.00-P-1001-06D |
| 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 | |
| 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 contact with 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 | |
| Risk of injury
to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. |
Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the overpressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. |
AS20.00-Z-0001-01A | |
| 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 | |
| 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 | |
| Notice | Notes on coolant | AH20.00-N-2080-01A | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| Notice | Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | |
| Notice | 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 | ||
| Notes on coolant level | AH20.00-P-1142-01CW | ||
| 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. | ||
ME-SFI [ME] control unit→ Actuation→ Actuate the fuel pump. |
AD00.00-P-2000-04B | ||
| 2 | Disconnect ground line of on-board electrical system battery (G1). | AR54.10-P-0003LW | |
| 3 | Remove rear Engine cover. | AR01.10-P-2408MRI | |
| 4 | Remove Engine wiring harness. | Do not kink lines, do not subject lines to tension. Otherwise damage will occur. |
AR15.18-P-1000-04MRH |
| Fig 4 | |||
| Fig 2 | |||
| 5 | Release shielding (1) in reverse order to the tightening procedure and remove. | Tightening procedure for high-pressure pump shielding | AR07.02-P-0815-01MRH |
| 6 | Remove soundproofing of the high-pressure pump. | ||
| Clean | |||
| 7 | Clean area around the high-pressure pump, the high-pressure line (2), and the rail (3). | Assembly cleaner | *BR00.45-Z-1028-04A |
| 8 | Release fuel pressure in the fuel high-pressure circuit. | AR07.03-P-1460-02MM | |
| 9 | Remove high-pressure line (2) and seal connections with suitable stop plugs. | Do not kink or bend high-pressure line (2). Leaks can occur otherwise. |
|
| Fig 7 | |||
| Fig 4 | |||
| 10 | Remove the intake camshaft valve lift changeover actuator (Y49/8). | AR05.20-P-6560MRI | |
| 11 | 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. | |
| 12 | Remove hold-down tools (4). | ||
| 13 | Remove screws of the rail (3) in reverse order of the tightening procedure. | Rail tightening procedure | AR07.03-P-1010-06MRH |
| 14 | Remove rail (3) and seal connections with suitable stop plugs. | Fig 4 | |
| 15 | Pull fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4 out of cylinder head and seal injector shaft holes with suitable stop plugs. | AR07.03-P-0004-03MM | |
| Fig 3 | |||
| Fig 6 | |||
| 16 | Remove fuel pressure and temperature sensor (B4/25). | If a new rail (3) is installed. | |
| AR07.04-P-0093MRI | |||
| Check | |||
| 17 | Check fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) for external damage. | 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. If damage is present: ↓ replace corresponding fuel injector. |
|
| 18 | Check high-pressure line (2) and replace if necessary. | AR07.03-P-1010-03MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Clean | |||
| 19 | 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 | |||
| 20 | Install new sealing packages of the rail (3). | AR07.03-P-0004-02MM | |
| Assembly cleaner | *BR00.45-Z-1028-04A | ||
| Fig 8 | |||
| 21 | Install new sealing rings (5, 6) 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. | |
| 22 | Install new sealing rings (7) 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 | ||
| Fig 5 | |||
| 23 | Remove stop plugs of injector well bores. | Fig 3 | |
| 24 | Install fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4) in rail (3) and secure with hold-down tools (4). | 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. |
|
| 25 | Install rail (3) with fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4). | ||
| 26 | Tighten screws of the rail (3). | Rail tightening procedure | AR07.03-P-1010-06MRH |
| *BA07.52-P-1001-01K | |||
| 27 | Install fuel pressure and temperature sensor (B4/25). | If a new rail (3) is installed. | |
| AR07.04-P-0093MRI | |||
| 28 | Install high-pressure line (2). | Do not kink or bend high-pressure line (2). Leaks can occur otherwise. |
|
| *BA07.03-P-1001-01I | |||
| Fig 7 | |||
| 29 | Install the intake camshaft valve lift changeover actuator (Y49/8). | AR05.20-P-6560MRI | |
| 30 | Install soundproofing of the high-pressure pump. | ||
| 31 | Install shielding (1). | Tightening procedure for high-pressure pump shielding | AR07.02-P-0815-01MRH |
| *BA07.02-P-1002-02A | |||
| 32 | Install Engine wiring harness. | AR15.18-P-1000-04MRH | |
| *BA15.18-P-1002-01K | |||
| *BA15.18-P-1001-01K | |||
| *BF20.00-P-1001-06D | |||
| Fig 4 | |||
| Fig 2 | |||
| 33 | Attach ground line of the on-board electrical system battery (G1). | AR01.10-P-2408MRI | |
| 34 | Read out fault memory with vehicle diagnosis system and delete if necessary. | ||
| AD00.00-P-2000-04B | |||
| 35 | Store injector quantity compensation coding in motor control module (MCM). | When installing new fuel injectors (Y76/1, Y76/2, Y76/3, Y76/4). | |
| AD00.00-P-2000-04B | |||
| Check | |||
| 36 | Check Engine cooling system for leak tightness. | AR20.00-P-1010LW | |
| 37 | Check the fuel high-pressure circuit. | AR07.03-P-1010-04MM | |
| AD00.00-P-2000-04B | |||
| 38 | Perform Engine test run. While doing so, check Engine for proper operation and leak tightness | ||
| 39 | Remove the Engine cover at the rear. | AR01.10-P-2408MRI |
FUEL SYSTEM HIGH PRESSURE PUMP
| Number | Designation | Engine 264 | |
|---|---|---|---|
| BA07.02-P-1002-02A | Bolt for high-pressure pump shielding | Nm | 20 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 264 | ||
|---|---|---|---|---|
| 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 264 | |
|---|---|---|---|
| BA07.52-P-1001-01K | Screw/bolt, fuel distributor to cylinder head cover | Nm | 8 |
Engine WIRING HARNESS
| Number | Designation | Engine 264 | ||
|---|---|---|---|---|
| BA15.18-P-1001-01K | Bolt, Engine wiring harness to cylinder head cover | M6 | Nm | 8 |
Engine WIRING HARNESS
| Number | Designation | Engine 264 | |
|---|---|---|---|
| BA15.18-P-1002-01K | Engine cover ball head to Engine wiring harness cable duct | Nm | 8 |
COOLING SYSTEM
| Number | Designation | Engine 264 in Model 205 (except 205.080) | Engine 264 in Model 205.080 | |||
|---|---|---|---|---|---|---|
| BF20.00-P-1001-06D | Cooling system | Workshop replacement amount | Main circuit | Liter | ≈ 8, 6 | ≈ 10, 0 |
| Low-temperature circuit | Liter | - | - | |||
| Antifreeze/water | Down to -37 °C | % | 50/50 | 50/50 | ||
| -38 °C and below | % | 55/45 | 55/45 | |||
| Specifications for Fluids | Operating | BB00.40-P-0310-01A | BB00.40-P-0310-01A | |||
| Specifications for Fluids | Operating | BB00.40-P-0325-06A | BB00.40-P-0325-06A | |||
| Specifications for Fluids | Operating | BB00.40-P-0326-06A | BB00.40-P-0326-06A | |||
COOLING SYSTEM
| Number | Designation | Engine 264 in Model 253 with code B01 | Engine 264 in Model 253 except code B01 | |||
|---|---|---|---|---|---|---|
| BF20.00-P-1001-06D | Cooling system | Workshop replacement amount | Main circuit | Liter | ≈13, 0 | ≈13, 0 |
| Low-temperature circuit | Liter | ≈4, 0 | - | |||
| Antifreeze/water | Down to -37 °C | % | 50/50 | 50/50 | ||
| -38 °C and below | % | 55/45 | 55/45 | |||
| Specifications for Fluids | Operating | BB00.40-P-0310-01A | BB00.40-P-0310-01A | |||
| Specifications for Fluids | Operating | BB00.40-P-0325-06A | BB00.40-P-0325-06A | |||
| Specifications for Fluids | Operating | BB00.40-P-0326-06A | BB00.40-P-0326-06A | |||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1028-04A | Assembly cleaner | A 000 986 56 01 |