Remove/install injectors

AR07.16-D-1000WE

Remove/install injectors

18.02.2020

Engine

651 in model 900

Engine

651.955/956/957 in model 906

Modification notes

16.07.2018

Relevant information on storing the fuel injectors inserted

Operation step 7

16.07.2018

Information on the grommets to be used added

Operation steps 4, 7

Shown on model 906 without code MS3 (emissions level Euro 3)

1

Leak oil line

5

Cable duct

Y76/14

Injector cylinder 1

2

Electrical connector

6

Electrical connector

Y76/15

Injector cylinder 2

3

Lock

7

Screw

Y76/16

Cylinder 3 injector

4

Bracket

8

Clamping claw

Y76/17

Cylinder 4 injector

 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 threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on injectors

AH07.16-P-1000-01S

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove injection lines.

AR07.16-D-1080WE

2

Remove right bracket (4) from firewall.

If injector for cylinder 3 (Y76/16) or injector for cylinder 4 (Y76/17) are removed.

AR09.10-D-1150-03SF

3

Disconnect electrical connection (6).

 Installation: Replace seals.

4

Release locks (3) in the direction of the arrow and remove leak oil line (1) from fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17).

 Catch fuel coming out with a clean dry cloth. Seal connections with grommets.
Grommets to be used, see EPC. Replacement part number: A 000 982 89 09

 Installation: Check sealing rings on leak oil line (1) for damage.

Depending on the findings,



Replace leak oil line (1).

5

Disconnect electrical connectors (2) from fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17) and place cable duct (5) to one side.

6

Remove clamping claws (8).

 To do this, remove screws (7) and remove clamping claws (8).

 Installation: Replace the screw/bolts (7).

 Installation: Check threaded bushings for damage.

 Bolt, clamping claw to fuel injector

*BA07.16-N-1003-01A

Depending on the findings,



replace damaged threaded bushing in the cylinder head.

AR07.03-D-0815-01W

Check values for threaded bushing

*BE07.16-D-1001-01B

Mounting adhesive, Loctite 648

*BR00.45-Z-1010-02A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

7

Remove fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17).


The fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17) must be stored vertically (connections upward) and must not be laid on their side.
This prevents air entering the fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17), which could cause engine starting or running problems when they are reinstalled.

 Removal: Mark assignment of the fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17) relative to the corresponding cylinders.

 Seal connections on fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17) with grommets.
Grommets to be used, see EPC. Replacement part number: A 000 982 89 09

 Installation: Assign fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17) to the corresponding cylinders.
Install new sealing rings and coat injector shafts with special grease.

Special grease

*BR00.45-Z-1036-06A



Clean

8

Clean fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17) and injector wells.

 Round brush

*611589006800

 Cylinder brush

*668589006800

9

Install in the reverse order.

10

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

If new fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17) were installed.



AD00.00-D-2000-04SD

If stored faults are shown,



Erase the fault memory.



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

11

Perform engine test run, switch off engine, and check leak tightness of the fuel system in the area of the fuel injectors (Y76/14, Y76/15, Y76/16, Y76/17).

 Visual inspection only.

Check values for injector

Number

Designation

Engine 651 in model 900, 906

BE07.16-D-1001-01B

Check values for threaded bushing

Reference value

Nm

20

Screw-in dimension

mm

37 (1,0)

 Common rail diesel injection (CDI)

Number

Designation

Engine 651 in model 900

Engine 651 in model 906

BA07.16-N-1003-01A

Bolt, clamping claw to fuel injector

Stage 1

Nm

15

15

Stage 2

°

90

90

Stage 3

°

90

90

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-02A

Mounting adhesive, Loctite 648

A 003 989 32 71 10

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09