Remove/Install Fuel Distributor With Fuel Injectors - AR07.03-P-1055MFC
Engine 260 in model 118, 177, 247
MODIFICATION NOTES
| 04.11.2019 1 | Document completely revised. | 1 |
Shown on engine 260 with code M016 (performance-enhanced engine)
| 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 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 . 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 | |
| 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 | |
| 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 avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | |
| Notice | Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | |
| Notice | 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 of 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. | Fig 6 | |
| Fig 3 | |||
| 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. | Fig 6 | |
| 7 | Remove molded hose (4) and seal openings with protective covers. | Engine 260 with code M016 (Uprated engine) |
|
| Fig 1 | |||
| Fig 8 | |||
| Fig 2 | |||
| 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 | |
| Fig 9 | |||
| 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. |
|
| Fig 6 | |||
| Fig 4 | |||
| 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. | Fig 6 | |
| 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 | |
| Fig 10 | |||
| Fig 5 | |||
| 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 | ||
| Fig 6 | |||
| 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 | ||
| Fig 11 | |||
| 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 | ||
| Fig 7 | |||
| 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. 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 |
| *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. |
|||
| *BA07.03-P-1001-01I | |||
| Fig 4 | |||
| 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 | |
| *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) |
|
| Fig 1 | |||
| 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. | ||
| *BA01.20-P-1008-03C | |||
| 33 | Attach ground line of 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 High-Pressure fuel 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 |