Remove/install fuel injectors

AR07.16-S-1020PD

Remove/install fuel injectors

18.04.2019

Model

470, 471 with engine 699

1

Fuel injectors

2

Clamping claw

3

Bolts

4

Electrical connectors

 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

1

Remove leak oil line at fuel injectors (1)

AR07.03-S-9105PD

2

Remove high-pressure lines (1) to fuel injectors

AR07.16-S-1003PD

3

Disconnect electrical connectors (4)

4

Remove screws (3)

5

Remove fuel injectors (1) with sealing rings and clamping claws (2)

 Mark assignment of fuel injectors (1) to corresponding cylinder.



Clean

6

Clean fuel injectors (1) and injector wells

 Cylinder brush

*668589006800

 Round brush

*611589006800



Install

7

Install fuel injectors (1) with sealing rings and clamping claws (2)


Make sure fuel injectors (1) with sealing rings and clamping claws (2) are positioned correctly.
Otherwise, individual components can be damaged.

 Assign fuel injectors (1) to corresponding cylinder.

 Replace sealing rings and clamping claws (2), and coat injector shafts with special grease.

Special grease

*BR00.45-Z-1036-06A

8

Prepare seat of clamping claws (2) in new cylinder head

Only when replacing cylinder head.

 To do this, screw in bolts (3), tighten, and unscrew again.

 Initial torque of bolt for clamping claw of fuel injector on cylinder head

*BA07.16-N-1002-03PD

9

Screw in screws (3)

 Replace screw/bolts (3).

 Screw/bolt, injection nozzle clamping claw to cylinder head

*BA07.16-N-1001-03PD

10

Connect electrical connections (4)

11

Install high-pressure lines to fuel injectors (1)

AR07.16-S-1003PD

12

Attach leak oil line to fuel injectors (1)

AR07.03-S-9105PD

13

Enter classification of fuel injectors (1) in control unit

Only when replacing fuel injectors (1).



AD00.00-S-2000-06P



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

14

Check for leak tightness with engine running

 Visual inspection only.

 Common rail diesel injection system

Number

Designation

Model 470, 471 with engine 699

BA07.16-N-1001-03PD

Screw/bolt, injection nozzle clamping claw to cylinder head

Stage 1

Nm

7

Stage 2

°

180

 Common rail diesel injection system

Number

Designation

Model 470, 471 with engine 699

BA07.16-N-1002-03PD

Initial torque of bolt for clamping claw of fuel injector on cylinder head

New cylinder head

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10