Remove/install injectors · ar0716p1000olf · Mercedes-Benz WIS

AR07.16-P-1000OLF

Remove/install injectors

18.02.2020

Engine

651 in model 222

6	Leak oil line
22	Fuel injector
A	Leak oil line connection not locked
B	Leak oil line connection locked

P07.16-4136-04

P07.16-4135-07

1	Electrical connector	4	Sealing ring
2	Screw	22	Fuel injector
3	Clamping claw

5	Identification plate
22	Fuel injector

P07.16-4137-11

 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
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
 	Remove/install
1	Remove upper engine cover
2	Unlock locks for leak oil line connections and detach leak oil line (6) at fuel injectors (22)	 Observe lock for leak oil line connections: in the locked condition a white marking (arrow) is visible is visible (picture B). The white marking (arrow) is not visible (picture A) in a not locked condition .
		 Installation: Wet the sealing rings for the leak oil line connections with lubricant.
		 Catch escaping fuel with a clean, lint-free dry cloth.
		 Installation: Check sealing rings for the leak oil line connections for damage.
		Special lubricant	*BR00.45-Z-1055-06A
		If damage is present:
		
		Replace leak oil line (6).
3	Release and disconnect electrical connection (1) at fuel injectors (22)	 Press safety catch with needle nose pliers together.
		 Installation: Replace sealing rings and housing cover on the electrical connections.
4	Remove injection lines between rail and fuel injectors (22)		AR07.16-P-1080OLF
5	Remove screw/bolts (2)	 Installation: Replace screw/bolts (2) and tighten in stages.
		 Installation: Determine the difference in height using a straight edge through simultaneous placing on of the identification plate (5) for all fuel injectors (22). In this way one can ensure that the fuel injectors (22) are installed correctly. For differences in height of the fuel injectors (22) a sealing ring (4) is missing or there is one sealing ring (4) too many installed.
		 Screw/bolt, clamping claw to injector	*BA07.16-P-1005-01H
		 Straightedge	*452589019924
6	Remove clamping claw (3)
7	Mark fuel injectors (22) relative to the cylinders appropriately using a colored pencil	 Mark fuel injectors (22) in order to assign the fuel injectors (22) to the respective cylinders during installation.
8	Remove fuel injectors (22)	 Installation: Replace seals (4). Coat stem of the fuel injectors (22) with special grease.
		Special grease	*BR00.45-Z-1036-06A
		If the fuel injectors (22) are jammed in place:
		
		Remove jammed fuel injectors.
			AR07.16-P-1000-03CD
		 Impact extractor	*602589003300
		 Bei Delphi-Injektoren Extraction claw	*651589003300
		 Bei Bosch-Injektoren Threaded adapter	*642589013300
9	Close off connections at fuel injectors (22) with a suitable grommet	 Grommets are available as an replacement part of the fuel injection system; see EPC Group 07. Repeated usage of stop plugs is not allowed. Ensure scrupulous cleanliness!
10	Check the threaded bushing	 Check for damage to the thread and jamming.
		 Threaded insert for bolt, clamping claw to cylinder head	*BA07.16-P-1010-01H
		Mounting adhesive, Loctite 648	*BR00.45-Z-1010-02A
		Loctite 7063 (400 ml) cleaning spray	*BR00.45-Z-1046-04A
		For a loosened threaded bush or damaged thread
		
		Remove threaded bushing and blow out thread in cylinder head and clean. Replace the threaded bush.
		 Installation: Apply adhesive thinly and apply evenly to the new threaded bushing. Screw the threaded bushing into the collar in the cylinder head and caulk with a center punch mark.
		 Installation: Allow adhesive material to cure for at least 6 h. Only install injection nozzle (22) after curing the adhesive.
	Clean
11.1	Clean fuel injectors (22) and fuel injector shafts with a round wire 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 (22) and fuel injector wells using a round and cylinder brush	In a case strong carbonization
		 Clean seat free of residues. Damage can occur on the cylinder head otherwise.
		 Round brush	*611589006800
		 Cylinder brush	*668589006800
12	Install in the reverse order
13	Connect diagnostic system, read out fault memory and perform a control unit adaptation	For replacement of one or more fuel injectors (22)
			AD00.00-P-2000-04B
		 For installation of new fuel injectors (22), a control unit adaptation must take place in order to store the "IMA 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	Carry out an engine test run and check fuel injection systems for leaktightness

 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

642 589 01 33 00

Threaded adapter

602 589 00 33 00

Impact extractor

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

ad0000p200004b Connect STAR DIAGNOSIS and read out fault memory
ah0000p500001a Notes on avoiding damage through contamination and foreign objects
ah0716p100001a Notes on injectors
ar0716p100003cd Remove jammed fuel injectors
ar0716p1080olf Remove/install injection lines of common rail direct injection
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.
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.