Remove/install injectors

AR07.16-D-1000SF

Remove/install injectors

24.07.2020

Engine

642.896/898/992/993 in model 906

Modification notes

22.07.2020

Work procedure revised.

The whole document

Shown with engine 642.992 at cylinder 4 

1

Injection line

Y76/1

Injector cylinder 1

Y76/4

Cylinder 4 injector

2

Screw

Y76/2

Injector cylinder 2

Y76/5

Cylinder 5 injector

3

Clamping claw

Y76/3

Cylinder 3 injector

Y76/6

Cylinder 6 injector

4

Sealing ring

 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

Topical note

Notes on injectors

AH07.16-P-1000-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

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

AH00.00-P-0020-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX



Remove

1

Remove injection line (1) of respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

AR07.16-D-1080SF

2

Disconnect electrical connector of respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

3

Unscrew screw (2) at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

 Bolt, clamping claw to injector

*BA07.16-N-1001-01B

4

Remove clamping claw (3) at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

5

Remove respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).


Store removed injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6) upright.
Malfunctions of respective injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6) can otherwise occur.

 When removing several injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6), mark these assigned to the cylinders.

If one or more injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6) are stuck:



Remove affected injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

AR07.16-S-1000-03SE

 Impact extractor

*355589016300

 Threaded adapter

*642589013300

If stuck cylinder 6 injector (Y76/6) will be removed:



Remove brake booster.

AR43.10-D-0350H



Clean

6

Clean respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

7

Clean injector well at cylinder head of respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6) with a brush.

 Round brush

*611589006800

 Cylinder brush

*668589006800



Install

8

Remove sealing ring (4) at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

 Replace compression ring (4).

9

Install respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

 Observe markings and respective assignment of cylinders during installation of several injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

 Grease well at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

Special grease

*BR00.45-Z-1036-06A

10

Install clamping claw (3) at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

11

Screw in screw (2) at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

 Replace screw (2).

 Bolt, clamping claw to injector

*BA07.16-N-1001-01B

12

Connect electrical connector of respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

13

Install injection line (1) of respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).

AR07.16-D-1080SF

14

Connect vehicle diagnosis system, read out fault memory, and enter injector classification in the CDI control unit.

When replacing the respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-D-2000-04SD

15

Remove diagnostic system.

When replacing the respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).



Check

 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

16

Check for leaktightness when engine is running.

 Visual inspection only.

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.896/898/992/993 in model 906

BA07.16-N-1001-01B

Bolt, clamping claw to injector

Stage 1

Nm

7

Stage 2

°

180

Repair materials

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10