Remove/install injectors

AR07.16-P-1000GD

Remove/install injectors

20.7.06

20.2.06

Bolt, tensioning claw to injector

*BA07.16-P-1001-01B

 

Remove/install

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove induction module

AR09.20-P-1400GD

2

Remove primary catalytic converter (near-engine mounted)

AR49.10-P-5510GD

3

Remove turbocharger

AR09.40-P-6020GD

4

Pull out fuel injector connector (50/1) at fuel injectors (Y76)

5

Remove injection lines (21/6) for common rail diesel injection (CDI)

AR07.16-P-1080GD

6

Remove heat shield (1)

7

Detach the leak oil line (50/6)

 Installation:A removed securing clamp (3) must not be reused. A new securing clamp must be used in order to guarantee a secure fitting of fuel injectors (Y76).

 For this purpose, press in securing clamps (3) at leak oil line connections (50/6) (arrows).

 Locking clamps (3) remain on fuel injectors (Y76).

8

Unscrew Torx bolt (5)

 Installation: Make sure that external Torx bolt intended for use with engine 668 and not internal Torx bolt for engine 611 to prevent damage to thread.

 If the Torx bolt (5) is torn off during removal or the thread in cylinder housing is damaged, see:



Thread repair for clamping claw mount

AR07.16-P-1000-02A

 Installation: Always replace Torx bolts (5).

Bolt, clamping claw to injector

*BA07.16-P-1001-01B

 Heli-Coil tool

*000589189900

9

Pry out fuel injectors (Y76) and clamping claw (4)

Installation: Following removal using the threaded adapter, all fuel injectors (Y76) must be replaced to guarantee their trouble-free operation.

 Installation: Replace sealing rings (50/13) to prevent leaks.

 Installation: Replace bolts of clamping claws (4) to guarantee their trouble-free operation.

 Mark fuel injectors (Y76) to position fuel injectors (Y76) at original points when installing

 When installing new injectors (Y76), control units must be adapted using STAR DIAGNOSIS to store injector quantity compensation coding in CDI control unit (N3/9). Present on the vehicle

Make the adhesive label irrecognisable according to injector quantity compensation coding.

 Installation: For tension-free installation of injection lines (21/6), injection lines (21/6) must be fitted on before tightening fuel injectors (Y76).

 Use a suitable screwdriver to lever out fuel injectors (Y76) and tensioning claw (4) together

 If the fuel injectors (Y76) are tight, use clamping pliers (6) and the impact extractor (7), if necessary:



Remove injectors with threaded adapter

AR07.16-P-1000-01A

 If the fuel injectors (Y76) cannot be removed also with clamping pliers (6) and impact extractor (7) or thread adapter, see:



Remove frozen fuel injectors

AR07.16-P-1000-03B

 Clamping pliers

*668589003400

 Impact extractor

*602589003300



Cleaning

10

Clean fuel injectors (Y76) and injector recesses

 Close injector recesses before cleaning with a pin to prevent internal damage due to ingress of foreign matter.

 Clean injector recesses and fuel injectors (Y76) with a wire brush, grease injector recesses using special grease, clean, blow out and cover injector recesses with a round brush and cylinder brush and then clean again using soft cloths to guarantee their trouble-free function.

 Fuel injectors (Y76) must not be disassembled.



Notes on injectors

AH07.16-P-1000-01A

Round brush

*611589006800

Cylinder brush

*668589006800

 Brake caliper brush

*000589266800

Special grease

*BR00.45-Z-1036-06A

11

Install in the reverse order



Checking

 Danger!

Risk of explosion from 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 the system when it is pressurized.

AS07.16-Z-0001-01A

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

12

With the engine running, check for leaks in fuel system around fuel injectors (Y76)

 Carry out visual inspection.

13

Read out fault memory and erase

 Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in the fault memories after completing the work.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

*WH58.30-Z-1048-13A

Number

Designation

Engine 668.940/
941/942

BA07.16-P-1001-01B

Bolt, tensioning claw to injector

Stage 1

Nm

7

Stage 2

°

90

Stage 3

°

90

Number

Designation

WH58.30-Z-1048-13A

STAR DIAGNOSIS diagnosis system, Compact Passenger Car

6511 1801 00

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10