Remove/install injectors · ar0716p1000cd · Mercedes-Benz WIS

AR07.16-P-1000CD

Remove/install injectors

18.02.2020

Engine

651 in model 166, 172, 204, 207, 212, 218, 221

P07.16-3443-07

1	Electrical connector	4	Sealing ring
2	Screw	Y76	Fuel injectors
3	Clamping claw

5	Identification plate
Y76	Fuel injectors

P07.16-3816-11

6	Leak oil line
Y76	Fuel injectors
B	Locked
A	NOT LOCKED

P07.16-3922-04

 Warning	Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.	No parts of the body or limbs should be within the operating area when the components are moving.	AS00.00-Z-0011-01A
 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
 	Remove/install
1	Remove top engine cover
2	Disconnect leak oil line (6)	 Installation: Wet the sealing rings for the leak oil connections using special lubricant.
		 Observe lock for leak oil line connection: in the locked condition a white marking is visible (picture B). In a not locked condition the white marking is not visible (picture A).
		Special lubricant	*BR00.45-Z-1055-06A
3	Remove injection lines between rail and fuel injectors (Y76)		AR07.16-P-1080CD
4	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.
5	Remove screw/bolts (2)	 Installation: Replace screw/bolts (2). Tighten screw/bolts (2) in stages. Determine the difference in height using a straight edge through simultaneous placing on of the identification plate (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
6	Check threaded sleeve and thread on screw/bolts (2)	 Installation: Apply adhesive thinly and apply evenly to the new threaded bushing. Then screw this in to collar and caulk with a center punch mark.
		 Installation: Allow adhesive material to cure for at least 6 h. Only install after curing of the injection nozzle.
		For a loosened threaded sleeve or damaged thread
		
		Remove threaded sleeves and blow out thread in cylinder head, clean and replace the threaded sleeve.
		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	Mark fuel injectors (Y76) in order to assign the fuel injectors (Y76) to the respective cylinders.
9	Remove fuel injectors (Y76)	 Fuel injectors (Y76) must not reused when using an impact extractor and must be replaced. Orderly installation is not guaranteed otherwise.
		 Installation: Replace seals (4). Coat fuel injectors (Y76) with special grease.
		Special grease	*BR00.45-Z-1036-06A
		 Engine 651 in model 166, 172, 204, 207, 212, 218, 221In case of Bosch injectors Threaded adapter	*642589013300
		 Engine 651 in model 166, 172, 204, 207, 212, 218, 221In case of Delphi injectors Extraction claw	*651589003300
		 Impact extractor	*602589003300
		In case of jammed fuel injectors (Y76):
		
		Remove jammed fuel injectors.
			AR07.16-P-1000-03CD
10	Seal openings in the cylinder head using suitable stop plugs	 These are obtainable as a ET for the injection system; see EPC Group 07. Repeated usage of stop plugs is not allowed. Ensure scrupulous cleanliness!
	Clean
11.1	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.
		 Round brush	*651589016800
11.2	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.
		 Cylinder brush	*668589006800
		 Round brush	*611589006800
12	Install in the reverse order.
13	Connect diagnostic system and perform a control unit adaptation, read out fault memory and clear it if necessary	When replacing fuel injectors (Y76).
			AD00.00-P-2000-04A
		 For new fuel injectors (Y76) a control unit adaptation must take place over the diagnostic system in order to store the "IQC coding" in the CDI control unit. Make adhesive label with respective "IQC coding" illegible on the vehicle.
 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
14	Check fuel system for leaks with engine running	 Carry out visual inspection.

 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

668 589 00 68 00

Cylinder brush

452 589 01 99 24

Straightedge

651 589 01 68 00

Round brush

602 589 00 33 00

Impact extractor

642 589 01 33 00

Threaded adapter

611 589 00 68 00

Round brush

651 589 00 33 00

Extraction claw

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

Referenced documents

ad0000p200004a Connect STAR DIAGNOSIS and read out fault memory
ad0000p200004a
ah0716p100001a Notes on injectors
ar0716p100003cd Remove jammed fuel injectors
ar0716p1080cd Remove/install injection lines of common rail diesel injection (CDI)
as0000z000501a 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.
as0000z001101a Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.
as0716z000101a Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure
as4700z000101a 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.