Remove/install injectors

AR07.16-P-1000CD

Remove/install injectors

18.02.2020

Engine

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

1

Electrical connector

4

Sealing ring

2

Screw

Y76

Fuel injectors

3

Clamping claw

5

Identification plate

Y76

Fuel injectors

6

Leak oil line

Y76

Fuel injectors

B

Locked

A

NOT LOCKED

 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

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