Remove/install fuel injectors

AR07.03-P-0004OID

Remove/install fuel injectors

06.03.2020

Engine

656 in model 167

Modification notes

27.11.2019

Bolt, injector clamping claw to cylinder head

BA07.16-P-1005-04A

14.01.2020

Special tools 270 589 03 91 00 and 355 589 01 63 00 added.

1

Leak oil line

2

Screw

3

Clamping claw

4

Seal

Y76/1

Cylinder 1 fuel injector

Y76/2

Cylinder 2 fuel injector

Y76/3

Cylinder 3 fuel injector

Y76/4

Cylinder 4 fuel injector

Y76/5

Cylinder 5 fuel injector

Y76/6

Cylinder 6 fuel injector

 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

 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

 Warning

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

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove injection lines.

AR07.16-P-1080OID

2

Remove leak oil line (1) from fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6).

AR07.03-P-9105OID

3

Remove screws (2).

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

 Installation: Replace screw/bolts (2).

 Bolt, injector clamping claw to cylinder head

*BA07.16-P-1005-04A

4

Remove clamping claws (3).

 Installation: Replace clamping claws (3).

5

Clean area around the fuel injectors for cylinders 1   to6 (Y76/1 to Y76/6).

Assembly cleaner

*BR00.45-Z-1028-04A

6

Mark fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6) relative to the corresponding cylinders.

If fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6) are reused.

7

Remove fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6).

 Installation: After removal of fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6) using  impact extractor, replace fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6).
Replace seals (4).
Coat injector shafts with special grease.
If fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6) are reused, observe the markings.

Special grease

*BR00.45-Z-1036-06A

 Impact extractor

*355589016300

8

Clean injector wells and seal openings with stop plugs.


Clean seats without a residue.
Damage will otherwise occur on the cylinder head.

 Plug

*270589039100

If injector wells are slightly carbonized:



use a round brush.

 Round brush

*651589016800

If injector wells are severely carbonized:



use a round brush and a cylinder brush.

 Round brush

*611589006800

 Cylinder brush

*668589006800

9

Clean fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6).

In case of recycling.

If fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6) are slightly carbonized:



use a round brush.

 Round brush

*651589016800

If fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6) are severely carbonized:



use a round brush and a cylinder brush.

 Round brush

*611589006800

 Cylinder brush

*668589006800

10

Install in the reverse order.

11

Read out and delete fault memory.



AD00.00-P-2000-06ME

12

Perform control unit adaptation and store injector quantity compensation coding in the engine management control unit.

After replacing one or more fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6).



AD00.00-P-2000-06ME

13

On the vehicle make an adhesive label with respective "IQC coding" illegible on the vehicle.

After replacing one or more fuel injectors for cylinders 1 to 6 (Y76/1 to Y76/6).

 Common rail diesel injection system

Number

Designation

Engine 656

BA07.16-P-1005-04A

Bolt, injector clamping claw to cylinder head

Stage 1

Nm

15

Stage 2

°

180

Stage 3

°

10

Repair materials

Number

Designation

Order number

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10