Check diesel injection system (code: 1406P07B30)

SM07.16-P-0010A

Check diesel injection system (code: 1406P07B30)

05.04.2016

Engine

651 in model 166

Modification notes

17.03.2016

Contents completely revised

Operation no. of the operation texts or standard texts and flat rates

Category

Op. no.

Operation text

Time

Acc. no.

Code

P

02-8926

Upgrade injection system to match current series production configuration

3

Seal

4

Firewall paneling

5

Connector sockets

6

Connector socket

7

Fuel filter

8

Connector socket

9

Blind cap

10

Connector socket

Y74

Pressure regulator valve

5

Connector sockets

11

Cable duct for injector wiring harness

12

Cable duct engine wiring harness

B4/6

High pressure fuel pressure sensor

12

Cable duct engine wiring harness

16

Fuel hose

18

Electrical line

19

Adapter line

20

Connector socket

21

Pin 2

22

Pin 1

23

Adhesive label

24

CDI control unit engine wiring harness

N3/9

CDI control unit

 Danger !

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Danger !

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Remove all ignition sources from hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A



Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A



Notes about Common-Rail components

AH07.16-P-0002-01TX



Check

1

Check whether vehicle is affected by measure

Model 166 as of 000001 up to 268498

SM07.16-P-0010-01AAA



Remove

2

Remove engine cover

3

Disconnect battery ground line



AR54.10-P-0003GZ

4

Remove seal (3) and remove firewall paneling (4)

5

Remove CDI control unit (N3/9) and air filter cover



AR07.08-P-7008CDA

 XENTRY Diagnostics is not yet required here.

6

Unplug all plug sockets (5, 6) from fuel injector (Y76/1, Y76/2, Y76/3, Y76/4) and camshaft Hall sensor (B6/1)

7

Release fuel filter (7) from bracket

8

Detach engine wiring harness cable duct (12) completely from bracket

 Place engine wiring harness cable duct (12) to one side.

9

Remove injector wiring harness cable duct (11)

 The injector wiring harness cable duct (11) is no longer required.

10

Disconnect plug socket (8) from pressure regulating valve (Y74)

11

Detach blind cap (9) from strapped down plug socket (10)



Install

12

Fit blind cap (9) onto plug socket (8)

 The plug socket (8) is no longer required.

13

Replace exhaust pressure sensor (B60)



AR07.04-P-0007CD

14

Replace rail



AR07.03-P-1010CD


Always use the pliers for click clamps special tool for the new click clamp.
Leaks can occur otherwise.

 Unfasten return line from click clamp. The banjo bolt remains on the old rail. Do not yet install any new high-pressure lines.

 Box wrench bit

*000589690300

 Pliers for click clamps

*171589003700

15

Fit plug socket (10) onto pressure regulating valve (Y74)

 To do so, branch-off plug socket (10). Ensure that routing of lines is correct. The branch-off line must be routed below the engine wiring harness cable duct (12).

16

Replace fuel hose (16)


Always use the pliers for click clamps special tool for the new click clamps.
Leaks can occur otherwise.

 Connect to fuel feed line first, then route adapter under engine wiring harness cable duct (12) and connect to leak oil line. Now fit the fuel hose (16) onto the fuel filter (7).

 Pliers for click clamps

*171589003700

17

Replace hot film MAF sensor (B2/5) with air intake pipe



AR07.07-P-1453CD

 Do not yet fit the hot film MAF sensor plug socket (B2/5).

18

Remove Pin 2 from hot film MAF sensor plug socket (B2/5), insulate it and strap it down on wiring harness

 The electrical line for Pin 2 from the engine wiring harness is no longer required.

19

Install electrical line (18) of adapter line (19) into PIN 2 of hot film MAF sensor plug socket (B2/5)

20

Connect hot film MAF sensor plug socket (B2/5)

21

Detach plug socket (20) from pressure sensor downstream of air filter (B28/5) and plug onto adapter line (19). Fit adapter line (19) to pressure sensor downstream of air filter (B28/5)

22

Detach plug socket from fuel pressure sensor (B4/6) and swap over Pin 1 (22) and Pin 2 (21)

 Blade holder with clamping pliers

*220589019950

23

Replace plug sockets (5) of injectors (Y76/1, Y76/2, Y76/3, Y76/4)

 Cut off and insulate the cable flush at all plug sockets (5), crimp on the new contacts with sealings and latch into the new connector housing (Pin 1 black, Pin 2 colored). Do not plug the plug sockets (5) onto the injectors (Y76/1, Y76/2, Y76/3, Y76/4) yet. Check contacts are securely seated!

24

Replace injectors (Y76/1, Y76/2, Y76/3, Y76/4)



AR07.16-P-1000CD



AR07.16-P-1080CD

 Do not yet install any new high-pressure lines.

 The special grease is to be used for approx. 10 vehicles. The special lubricant is to be used for approx. 25 vehicles.

Special grease

*BR00.45-Z-1036-06A

Special lubricant

*BR00.45-Z-1055-06A

25

Install injector line rail and fix in place using cable tie

 Route electrical lines to the injectors (Y76/1, Y76/2, Y76/3, Y76/4) in the sequence cylinder 1, camshaft Hall sensor (B6/1), cylinder 2, cylinder 3 out of the openings and mount cover. The line for cylinder 4 is routed straight out of the engine wiring harness.

 Do not tighten cable tie until the end when the high-pressure lines for the injectors have been tightened. This enables the wiring harness to be shifted towards the injector plugs to match.

26

Install injection lines for common rail diesel injection system (CDI)



AR07.16-P-1080CD

 Box wrench bit

*000589690300

27

Fit plug sockets (5) onto injectors (Y76/1, Y76/2, Y76/3, Y76/4)

28

Mount engine wiring harness cable duct (12)

29

Install new CDI control unit (N3/9) and new air filter cover



AR07.08-P-7008CDA

 Also insulate and correctly route CDI control unit engine wiring harness (24) in area (A). The adhesive tape can be used for approx. 20 vehicles.

30

Install bulkhead panels (4) and seal (3)

31

Connect ground cable to battery



AR54.10-P-0003GZ

32

Install new engine cover

Programming

33

Connect battery charger

34

Connect diagnostic unit

Use XENTRY Diagnostics Version 12/2015 or higher with all available add-ons. The operation steps must be performed exactly as per Xentry Diagnostics!



AD00.00-P-2000-04A

 In the CDI control unit (N3/9) enter the SA code "79o" at Special functions  Entry for retrofits and conversions.

 Then follow the user guidance in Xentry Diagnostics.

35

Manually commission new CDI control unit (N3/9).

 To do so, select menu item Control units view  Drive type  CDI motor electronics  Adaptations  Commission  Commission with manual setting of new control unit.

36

Disconnect diagnostic equipment



AD00.00-P-2000-04A



Check

 Danger !

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

37

Check fuel system for leaks with engine running

Repair materials

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10

BR00.45-Z-1055-06A

Special lubricant

A 000 989 36 60

Parts ordering note

Part no.

Designation

Quantity

A 651 010 84 12

Engine cover

1

A 651 070 63 87 05

Parts kit

1

A 007 989 07 85

Adhesive tape

n. B.

Small parts such as bolts, stop nuts, sealing rings, cable ties, fluids, sealant etc. are not listed in the parts list. The required small parts are taken into account in the cost framework.