Remove/install injectors

AR07.16-D-1000A

Remove/install injectors

21.2.06

20.2.06

Bolt, tensioning claw to injector

*BA07.16-P-1007-01A



Remove/install

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 contact with fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Remove top part of charge air distribution pipe

 Only on engine 611.981/983/987

AR09.41-D-1312A

2

Remove trim panel of cylinder head cover

AR01.20-D-5015A

3

Remove injection line (8)

AR07.16-D-1080A

4

Unplug connectors (7) at the injectors (1)

5

Remove locking clips (5) at the connections of the leak oil line (6) and place leak oil line (6) to the side

 Do not disassemble leak oil line, always replace complete if necessary.

6

Unscrew stretch bolts (4)

Installation: Always replace stretch bolts (4). Tighten bolts in stages.



*BA07.16-P-1007-01A

7

Take out tensioning claw (3)

8

Pull out injectors (1)

 For engine with passenger car approval according to EU3
611.981 as of 446355
611.987 as of 445784
612.981 as of 445787
or for engine with truck approval according to Euro 3
611.981 as of 498370
611.987 as of 498370
612.981 as of 499019

the injectors are replaced, these must always be classified.

Mark the sequence when removing the injectors otherwise it is necessary to reenter the classification in the engine control unit with STAR Diagnosis.

 If injectors are tight, fit on extraction claw (10) in place of the tensioning claw (3) and use together with puller (9) to remove injector (1) together with seal (2).

Puller

*667589036300

Extraction claw

*611589013300

Installation: The injection lines must be fed in before tightening the injectors in order to install the injection lines free of tension.

9

Clean injectors (1) and injector recesses in cylinder head

 Use a suitable brush (brass bristles) to clean injector stems. Grease injector stems with special grease. Clean injector recesses with a round brush and cylinder brush, blow out and cover over. Seal injector recesses with pin before cleaning.

 Replace injector seal (2).



Notes on injectors

Engine 611.960/961/962/981/983/987, 612.961/962/963/981, 613.960/ 961, 628.960, 668.940

AH07.16-P-1000-01A

 Round brush

*611589006800

Cylinder brush

*668589006800

Special grease

*BR00.45-Z-1036-06A

If fuel injectors (Y76) cannot be removed with impact extractor or threaded adapter, see:

Remove frozen fuel injectors

AR07.16-D-1000-01A

10

Install in the reverse order

Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the running engine

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

Danger!

Risk of explosion from 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 the system when it is pressurized.

AS07.16-Z-0001-01A

11

Inspect fuel system for leaks

 Run engine, switch off and inspect for leaks.

Number

Designation

Engine 611.981/
987

Engine 611.983

BA07.16-P-1007-01A

Bolt, tensioning claw to injector

Stage 1

Nm

7

7

Stage 2

°

90

90

Stage 3

°

90

90

Number

Designation

Engine 612.981

BA07.16-P-1007-01A

Bolt, tensioning claw to injector

Stage 1

Nm

7

Stage 2

°

90

Stage 3

°

90

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10