Remove/install injectors

AR07.16-P-1000TX

Remove/install injectors

11.11.11

 

Remove/install

 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 systems when they are under pressure

AS07.16-Z-0001-01A



Notes about Common-Rail components

AH07.16-P-0002-01TX

1

Remove injection lines

AR07.16-P-1080TX

2

Unlock leak oil lines (1) from fuel injectors (Y76)

3

Detach leak oil lines (1) from fuel injectors (Y76)

 In order to avoid damage to fuel injectors (Y76) connectors, close off connections for leak oil lines (1) with a one-way protective cap and remove fuel residues.

4

Unlock connectors (2) from Fuel injectors (Y76) and detach

 To do this press together fuse link (3) using needle nose pliers and decontact with pressed together needle nose pliers.

5

Remove clamping claws (4) at fuel injectors (Y76)

 Mark clamping claws (4) in order to avoid material breakage through incorrect installation position.

 If bolt torn off during removal or the thread in the cylinder housing is damaged, see:



Thread repair for clamping claw mount

AR07.16-P-1000-02A

 Installation: Always replace bolts for clamping claws (4). Tighten bolts in stages.



*BA07.16-P-1004-01D

 Heli-Coil tool

*000589189900

6

Remove fuel injectors (Y76)

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

 Installation: Replace sealing rings. Coat fuel injectors (Y76) with special grease.

 Installation: With new injectors (Y76), a control unit adaptation via STAR DIAGNOSIS must take place in order to store injector quantity compensation coding in CDI control unit (N3/9). Present on the vehicle

Make adhesive label irrecognizable according to injector quantity compensation coding.

Impact extractor

*602589003300

Threaded adapter

*642589013300

Special grease

*BR00.45-Z-1036-06A



Cleaning

7

Clean fuel injectors (Y76) and injector recesses



Notes on injectors

AH07.16-P-1000-01A

 Round brush

*611589006800

 Cylinder brush

*668589006800

8

Install in the reverse order

9

Perform control unit adaptation

 When replacing injectors

STAR DIAGNOSIS diagnosis system



Checking

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

10

Check fuel system for leaks with engine running

 Carry out visual inspection.

11

Read out fault memory, erase if necessary

 Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

Number

Designation

Engine 646.8

BA07.16-P-1004-01D

Bolt, tensioning claw to injector

Stage 1

Nm

7

Stage 2

°

90

Stage 3

°

90

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10