Remove/install injectors

AR07.16-P-1000OLB

Remove/install injectors

18.02.2020

Engine

651 in model 117

Engine

651 in model 156

Engine

651 in model 176

Engine

651 in model 246

1

Electrical connector

3

Clamping claw

Y76

Fuel injectors

2

Screw

4

Sealing ring

5

Type plate

Y76

Fuel injectors

6

Leak oil line

Y76

Fuel injectors

 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

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

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove cylinder head cover trim

AR01.20-P-5014-02OLB

2

Unfasten engine wiring harness in area of fuel injectors (Y76) and place to one side

3

Disconnect leak oil line (6)

 Note locks for the leak oil line connections: the white marking is visible in a locked condition (picture B). The white marking is not visible in an unlocked condition (picture A).

 Installation: Wet the sealing rings for the leak oil line connections using special lubricant.

Special lubricant

*BR00.45-Z-1055-06A

4

Remove injection lines

AR07.16-P-1080OLB

5

Release and disconnect electrical connections (1) on fuel injectors (Y76)

 Installation: Replace sealing rings and housing cover on the electrical connections (1).

 To this do press safety catch with needle nose pliers together.

6

Remove screw/bolts (2)

 Installation: Generally replace screw/bolts (2).
Tighten screw/bolts (2) in stages.
Determine the difference in height using the  straight edge through placing at the same time on the identification plates (5). In this way one can ensure that the fuel injectors (Y76) are installed correctly. For differences in height of the fuel injectors (Y76) a sealing ring (4) is missing or there is a sealing ring (4) too many installed.

 Screw/bolt, clamping claw to injector

*BA07.16-P-1005-01H

 Straightedge

*452589019924

For a loosened threaded bush or damaged thread



Replace the threaded bush

 Remove threaded bushing and blow out thread in cylinder head and clean.

 Installation: For retaining the threaded bush, caulk this using a center punch mark.

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

Mounting adhesive, Loctite 648

*BR00.45-Z-1010-02A

 Threaded insert for bolt, clamping claw to cylinder head

*BA07.16-P-1010-01H

7

Remove clamping claw (3)

8

Remove fuel injectors (Y76) and close off line connections if necessary using stop plugs


Fuel injectors (Y76) must not be reused during use of an  impact extractor and must be replaced.
Orderly installation is not guaranteed otherwise.

 Mark fuel injectors (Y76) in order to assign the fuel injectors (Y76) to the respective cylinders.
Stop plugs are available as a replacement part of the diesel injection system, see EPC Group 07.
Repeated usage is not allowed.
Ensure utmost cleanliness.

 Installation: Replace seals (4). Coat fuel injectors (Y76) with special grease.

Special grease

*BR00.45-Z-1036-06A

 Impact extractor

*602589003300

 Extraction claw

*651589003300



Clean

9.1

Clean fuel injectors (Y76) and injector wells with a round brush

In case of light carbonization.


Clean seat free of residues.
Damage can occur on the cylinder head otherwise.

 The leak oil line O-rings must be oiled with a special lubricant for re-assembly.

Special lubricant

*BR00.45-Z-1055-06A

 Round brush

*651589016800

9.2

Clean fuel injectors (Y76) and injector wells using a round and cylinder brush

In a case of strong carbonization.


Clean seat free of residues.
Damage can occur on the cylinder head otherwise.

 The leak oil line O-rings must be oiled with a special lubricant for re-assembly.

Special lubricant

*BR00.45-Z-1055-06A

 Cylinder brush

*668589006800

 Round brush

*611589006800

10

Install in the reverse order

11

Connect the diagnostic system and perform control unit adaptation over the diagnostic system



AD00.00-P-2000-04A

 When replacing fuel injectors (Y76), their "IMA coding" must be stored in the CDI control unit.

 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

12

Check fuel system for leaks with engine running

13

Read out fault memory using the diagnostic system and delete if necessary



AD00.00-P-2000-04A

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1005-01H

Screw/bolt, clamping claw to injector

Stage 1

Nm

15

Stage 2

°

90

Stage 3

°

90

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1010-01H

Threaded insert for bolt, clamping claw to cylinder head

Nm

20

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

BR00.45-Z-1055-06A

Special lubricant

A 000 989 36 60