Remove/install injectors

AR07.16-P-1000TI

Remove/install injectors

15.11.2019

Engine

642 in model 211

Modification notes

20.02.2006

Screw/bolt, clamping claw to injector

BA07.16-P-1006-01C

1

Connector

5

Screw

21/6

Injection line

2

Securing clamp

6

Clamping claw

Y76

Fuel injectors

3

Leak oil line

7

Sealing ring

 

Remove/install

 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

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

 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

 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

1

Remove injection lines (21/6)

AR07.16-P-1080TI

2

Disconnect electrical connections (1) to fuel injectors (Y76)

3

Remove screw/bolt/bolts (5)

 Bolt, clamping claw to injector

*BA07.16-P-1006-01C

4

Remove clamping claw (6)

5

Remove fuel injectors (Y76)

 Installation: Replace screw/bolts (5) and sealing rings (7). Coat fuel injectors (Y76) with special grease.

 Mark fuel injectors (Y76) to position of fuel injectors (Y76) at original points when installing.

 When you install new injectors (Y76), control units must be adapted using STAR DIAGNOSIS to store the injector quantity compensation (IMA) coding in the CDI control unit (N3/9). Make the corresponding IMA coding on the
adhesive label illegible.

Special grease

*BR00.45-Z-1036-06A

 Impact extractor

*602589003300

 Threaded adapter

*642589013300



Clean

6

Clean fuel injectors (Y76) and fuel injector wells in cylinder head


To avoid damage,
always observe the notes on injectors.

 Round brush

*611589006800

 Cylinder brush

*668589006800

7

Install in the reverse order

8

Check fuel system for leaks with engine running

 Common rail diesel injection system (CDI)

Number

Designation

Engine 642

BA07.16-P-1006-01C

Bolt, clamping claw to injector

Stage 1

Nm

7

Stage 2

°

90

Stage 3

°

90

Repair materials

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10