Remove/install injectors

AR07.16-S-1000A

Remove/install injectors

21.2.06

20.2.06

Bolt, tensioning claw to injector

*BA07.16-P-1007-01A

 

Remove/install

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to 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

Ignition off

2

Remove mixing housing with exhaust gas recirculation

AR09.20-S-1330A

3

Remove trim panel of cylinder head cover (8)

AR01.20-S-5015A

4

Unplug connector (9) at injectors (Y20, Y21, Y22, Y23)

5

Detach injection lines (7)

 Counterhold using wrench at pressure pipe connection for injectors (Y20, Y21, Y22, Y23).

AR07.16-S-1080A

6

Remove leak oil line (3)

 Note routing of leak oil line (3).

 Unlock leak oil line (3) by pushing in the safety clamp (2). If the safety clamp (2) was removed then this must be replaced.

7

Remove exhaust gas recirculation pressure transducer/pressure control flap (Y84) at bracket

 Do not remove vacuum lines and connector.

8

Remove clamping claw (4) at injectors (Y20, Y21, Y22, Y23)

 Generally replace bolts (10).

Tighten bolts in stages.



*BA07.16-P-1007-01A

Torx bit set

*000589011000

 Screwdriver bit

*WH58.30-Z-1032-06A

9

Remove injectors (Y20,Y21,Y22,Y23)

Installation: Install new sealing ring (5).

The injection lines must be fed in before tightening injectors in order to install injection lines free of stress.

 If the injectors are tight, fit on extraction claw in place of tensioning claw and remove injector with impact extractor.

If the extraction claw on the cylinder head cover impacts, release this, see: 

Remove cylinder head cover

AR01.20-S-5014D

 Concerning the special tool: Replace bolt used in the specified impact extractor by a long-shafted bolt (M12x130) and a nut (M12). Mount impact extractor on newly fabricated special tool and lock using nut (M12).

 Impact extractor

*355589016300

Extraction claw

*611589013300



Notes on injectors

AH07.16-P-1000-01A

10

Clean injectors (1) and injector recesses in cylinder head

 Seal injector recesses with pin before cleaning.

Clean injector stems and injector recesses with fleece cloth.

Clean nozzle tips only with non-woven cloth.

Clean injector recesses with round and cylinder brush, blow out, clean with fleece cloth and cover up.

Clean injector stems with a wire brush and non-woven cloth and grease with special grease. Do not grease nozzle tips.

 Brake caliper brush

*000589266800

Round brush

*611589006800

Cylinder brush

*668589006800

Special grease

*BR00.45-Z-1036-06A

11

Install in the reverse order



Checking

 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 running engine

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

AS00.00-Z-0005-01A

 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

12

Inspect fuel system for leaks

 Run engine, switch off and inspect for leaks.

13

Read out fault memory and erase

Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed. See: 

Diagnosis Manual, Diesel Engine,
Volume 1.2

Number

Designation

Engine 611.980

BA07.16-P-1007-01A

Bolt, tensioning claw to injector

Stage 1

Nm

7

Stage 2

°

90

Stage 3

°

90

Number

Designation

WH58.30-Z-1032-06A

Screwdriver bit torx, 1/4 inch square, length 100 mm

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10