Remove/install injectors

AR07.16-L-1000VA

Remove/install injectors

21.2.06

20.2.06

Bolt, tensioning claw to injector

*BA07.16-P-1001-01B



Remove/install

1

Remove catalytic converter

AR49.10-P-5510GD

2

Remove turbocharger

AR09.40-L-6020VA

3

Unplug connector (7) at fuel injector (Y76)

Installation: Pay attention to the correct position of the connector (7).

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

4

Remove injection line (6)

AR07.16-L-1080VA

5

Take out screws (2) and remove heat baffle plate (1)

6

Press in locking clamps (3) at the connections of the leak oil line (8) (arrow) and detach leak oil line (8)

 Do not pull locking clamp (3) off fuel injector (Y76).

Installation: If the locking clamp (3) is pulled off, it is then necessary to install a new part.

7

Unscrew bolt (5)

 Installation: Install new self-locking bolt (5)
Ensure that the external Torx bolt intended for engine 668 is used, and not the internal Torx bolt for engine 611 (otherwise thread will be damaged).



*BA07.16-P-1001-01B

8

Unscrew bolts (11) and push exhaust gas recirculation pipe (12) to the side

9

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

 If new fuel injectors (Y76) are not fitted, mark the fuel injectors (Y76) and re-install at the same point.

 Puller

*667589036300

 Clamping pliers

*668589003400

 If the fuel injectors (Y76) are fixed tight, use clamping pliers (13) and puller (14), if necessary: 

Remove fuel injectors (Y76) with threaded adapter.

The injector (Y76) must always be replaced after being removed with the threaded adapter.

AR07.16-P-1000-01A

 Installation: Install new gasket (9) and sealing ring (10).

To ensure that injection lines (6) are installed free of tension, injection lines (6) must be fitted on before tightening fuel injectors (Y76).

 If the fuel injectors (Y76) cannot be removed with the clamping pliers (13) and puller (14) or thread adapter, see: 

Remove frozen fuel injectors

AR07.16-P-1000-03B

10

Clean fuel injectors (Y76) and injector recesses

 Clean injector stems and injectors with a wire brush. Grease injector stems with special grease. Clean injector recesses with a round brush and cylinder brush, blow out and cover over. After this, clean once again with non-woven cloth. Seal injector recesses with pin before cleaning.

The fuel injectors (Y76) must not be disassembled.



Notes on injectors

Engine 611.960/961/ 962/980/981/

987, 612.961/962/963/965/966/967/

981, 613.960/961,628.960/961/962/

963, 640, 642, 646.951/961/962/963,

647.961/981, 648.960/961,

668.914/940/941/942, 612.990

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

12

Read out fault memory



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 668.914

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