Remove/install injectors

AR07.16-S-1000E

Remove/install injectors

15.08.2019

Model

447 with engine 651

Modification notes

16.07.2018

Object information for storing the fuel-injectors and information on the grommets to be used

Operation step 7

1

Leak oil line

2

Clamping claw

Y76/9

Injector cylinder 1

Y76/10

Injector cylinder 2

Y76/11

Cylinder 3 injector

Y76/12

Cylinder 4 injector

 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 threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on injectors

AH07.16-P-1000-01S

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove air/water duct.

If injector for cylinder 3 (Y76/11) or injector for cylinder 4 (Y76/12) is removed.

AR83.25-S-1410E

2

Release engine wiring harness cable duct.

AR01.00-S-2411-01E

3

Remove injection lines.

AR07.16-S-1080E

4

Remove leak oil line (1) and place to one side.

AR07.03-S-9105E

5

Remove screws of the clamping claws (2).

 Installation: Replace the screw/bolts (2) of the clamping claws.

 Bolt, clamping claw to fuel injector

*BA07.16-N-1003-01A

6

Remove clamping claws (2).

7

Remove fuel injectors (Y76/9, Y76/10, Y76/11, Y76/12).


The fuel injectors (Y76/9, Y76/10, Y76/11, Y76/12) must be stored vertically (connections upward) and must not be laid on their side.
This prevents air entering the fuel injectors (Y76/9, Y76/10, Y76/11, Y76/12), which could cause engine starting or running problems when they are reinstalled.

 Removal: Mark assignment of the fuel injectors (Y76/9, Y76/10, Y76/11, Y76/12) relative to the corresponding cylinders.

 Seal connections on fuel injectors (Y76/9, Y76/10, Y76/11, Y76/12) with grommets.
Grommets to be used, see EPC. Replacement part number: A 000 982 89 09

 Installation: Assign fuel injectors (Y76/9, Y76/10, Y76/11, Y76/12) to the corresponding cylinders.

 Install new sealing rings and coat injector shafts with special grease.

Special grease

*BR00.45-Z-1036-06A

If accessibility is not sufficiently guaranteed due to injector for cylinder 1 (Y76/9) or injector for cylinder 2 (Y76/10) becoming stuck,



Remove air/water duct.

AR83.25-S-1410E

If one or several of the fuel injectors (Y76/9, Y76/10, Y76/11, Y76/12) become stuck,



remove stuck fuel injectors (Y76/9, Y76/10, Y76/11, Y76/12).

AR07.16-S-1000-03E

 Impact extractor

*355589016300

 Extraction claw

*651589013300

 Baseplate

*651589076300



Clean

8

Clean fuel injectors (Y76/9, Y76/10, Y76/11, Y76/12) and injector wells.

 Round brush

*651589016800

 Round brush

*611589006800

 Cylinder brush

*668589006800

9

Install in the reverse order.

10

Connect vehicle diagnosis system, read out fault memory, and enter injector classification in the CDI control unit.

If new fuel injectors (Y76/9, Y76/10, Y76/11, Y76/12) were installed.



AD00.00-S-2000-04E

If stored faults are shown,



Erase the fault memory.



Check

 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

11

Check for leaktightness when engine is running.

 Visual inspection only.

 Common rail diesel injection (CDI)

Number

Designation

Engine 651 in model 447

BA07.16-N-1003-01A

Bolt, clamping claw to fuel injector

Stage 1

Nm

15

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