Clean injectors

AR07.16-D-0200A

Clean injectors

23.04.2019

Engine

651.955/956/957 in model 906

1

Connecting kit

2

Receptacle

3

Matra clamp

4

Matra clamp

Y76/14

Injector cylinder 1

Y76/15

Injector cylinder 2

Y76/16

Cylinder 3 injector

Y76/17

Cylinder 4 injector

1

Connecting kit

5

Pump

6

Manual valve

7

Safety valve

 Warning

Risk of injury caused by skin irritation and serious eye irritation if contact is made with DECON 90 injector cleaner

Avoid contact. Wear tight-sealing safety glasses and alkali-resistant protective clothing (apron).

AS07.03-Z-0002-01A

1

Connect Star Diagnosis

2

Perform a quick test

 Print out quick test check-in report and zero quantity calibration.

3

Remove air filter housing

AR09.10-D-1150WE

 Attach jump-start connection point to the firewall.

4

Remove engine cover

AR01.10-D-2405WE

Notes about Common-Rail components

AH07.16-P-0002-01TX

5

Remove injection lines

AR07.16-D-1080WE

6

Detach leak oil line from injectors

 Detach lock (arrow) upward.

7

Disconnect leak oil line with clamping device (3)

 Clamp

*000589403700

8

Connect receptacle (2) with external leak oil line

 Cleaning set

*651589006800

9

Clamp off fuel feed line upstream of fuel filter using a clamping device (4)

 Clamp

*000589403700

10

Connect connecting kit (1) to manual valve (6) and injectors and tighten

 Cleaning set

*651589006800

 Pump

*651589086300

11

Mix 0.25 liters of Decon 90 with 0.25 liters of water


To mix, pour the lye (Decon 90) into the water, not the other way around.
Otherwise, a severe reaction may occur.

Injector cleaner DECON 90

*BR00.45-Z-1075-04A

12

Apply a pressure to the pump (5) by hand of about 0.3 bar


Perform bleeding of the connection line only if the pressure is low.
Risk of injury for skin and eyes.

13

Release connection line of injector 4 and actuate manual valve until fluid comes out at the connection

 Cover area under the injector connection with rags so that escaping fluid is completely absorbed.

14

Tighten connection line again at injector

15

Connect battery charger

16

Actuate manual valve (6) and fix in place

 E.g. with cable tie.

17

Apply pressure of about 4.5 bar to the pump by hand

 During the pressure increase, check all connections of the connecting kit for leak tightness now and then.

18

In the STAR DIAGNOSIS menu CDI/D2, select actuations, injector

 Continue to follow instructions in the menu and actuate each injector for 4 minutes.

19

Allow the cleaning fluid to work for an hour

 The receptacle (2) is to be filled about two thirds with fluid. The system continues to remain under pressure.

20

Relieve pressure

 Actuate safety valve (red button) on pump.

21

Disconnect connecting kit

 Start at cylinder 4 so that as much fluid as possible flows out of the line into the hand pump. The receptacle with external return line continues to be connected.

22

Empty receptacle (2) and insert again

 Do not allow residual amount to get into the environment. Dispose of it in accordance with the specification.

23

Install injection lines

AR07.16-D-1080WE

24

Remove Matra clamp (4) from the fuel line

25

Insert air filter provisionally and connect

26

Allow engine to run for 10 minutes

27

Switch off engine and remove air filter again

 Check injection lines for leaktightness.

28

Remove receptacle (2) with an external leak oil line

 Dispose of diesel fuel from the receptacle in accordance with the specification.

29

Remove Matra clamp (3) from leak oil line

30

Disconnect battery charger

31

Connect leak oil line to the injectors

 Lock connections for leak oil lines again.

32

Install engine cover

AR01.10-D-2405WE

33

Install air filter housing

AR09.10-D-1150WE

34

Warm up engine to normal operating temperature

35

Perform quick teach in of injector using STAR DIAGNOSIS

36

Disconnect Star Diagnosis

37

Drain and rinse pump after use

 Do not allow residual amount to get into the environment. Dispose of it in accordance with the specification.

Repair materials

Number

Designation

Order number

BR00.45-Z-1075-04A

Injector cleaner DECON 90

A 002 986 33 71