Remove/install injectors

AR07.16-P-1000OLC

Remove/install injectors

06.03.2020

Engine

654 in model 213, 238, 257

Modification notes

27.11.2019

Bolt, injector clamping claw to cylinder head

BA07.16-P-1005-04A

14.01.2020

Special tools 270 589 03 91 00 and 355 589 01 63 00 added.

2

Screw

3

Clamping claw

4

Seal

5

Leak oil line

Y76/1

Cylinder 1 fuel injector

Y76/2

Cylinder 2 fuel injector

Y76/3

Cylinder 3 fuel injector

Y76/4

Cylinder 4 fuel injector

 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

 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

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove injection lines.

AR07.16-P-1080OLC

2

Remove leak oil line (5) from fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).

AR07.03-P-9105OLC

3

Remove screws (2).

Topical note

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

AH00.00-P-0020-01A

 Installation: Replace screw/bolts (2).

 Bolt, injector clamping claw to cylinder head

*BA07.16-P-1005-04A

4

Clean area around the fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).

Assembly cleaner

*BR00.45-Z-1028-04A

5

Mark fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) relative to the corresponding cylinders.

If the fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) are reused.

6

Remove fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) using clamping claws (3).

 Installation: Replace seals (4).
Replace clamping claws (3).
Coat injector shafts with special grease.

Special grease

*BR00.45-Z-1036-06A

If the fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) are reused,



observe the markings.

If the fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) are removed with an impact extractor,



replace fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).

 Impact extractor

*355589016300

7

Clean injector wells and seal openings with stop plugs.


Clean seats without a residue.
Damage will otherwise occur on the cylinder head.

 Plug

*270589039100

If injector wells are slightly carbonized:



use a round brush.

 Round brush

*651589016800

If injector wells are severely carbonized:



use a round brush and a cylinder brush.

 Round brush

*611589006800

 Cylinder brush

*668589006800

8

Clean fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).

In case of recycling.

If fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) are slightly carbonized:



use a round brush.

 Round brush

*651589016800

If fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) are severely carbonized:



use a round brush and a cylinder brush.

 Round brush

*611589006800

 Cylinder brush

*668589006800

9

Install in the reverse order.

10

Read out and delete fault memory.



Engine 654 in model 238

AD00.00-P-2000-06LWO



Engine 654 in model 213

AD00.00-P-2000-04B



Engine 654 in model 257

AD00.00-P-2000-06FR

11

Perform control unit adaptation and store injector quantity compensation coding in the CDI control unit (N3/9).

When installing one or more new fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).



Engine 654 in model 238

AD00.00-P-2000-06LWO



Engine 654 in model 213

AD00.00-P-2000-04B



Engine 654 in model 257

AD00.00-P-2000-06FR

12

Make the existing adhesive label with respective injector injection quantity adjustment coding illegible on the vehicle.

When installing one or more new fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).

 Common rail diesel injection system

Number

Designation

Engine 654

BA07.16-P-1005-04A

Bolt, injector clamping claw to cylinder head

Stage 1

Nm

15

Stage 2

°

180

Stage 3

°

10

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10