Remove/install injectors · ar0716d1000na · Mercedes-Benz WIS

AR07.16-D-1000NA

Remove/install injectors

21.2.06

ENGINE 612.981 in MODELS WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7

ENGINE 612.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada

ENGINE 612.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA

ENGINE 612.981 in MODELS 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico

D07.16-1191-06

1 Injector

2 Sealing ring

3 Clamping claw

4 Stretch bolt

5 Securing clamp

6 Leak oil line

7 Connector

8 Injection line

9 Puller

10  Extraction claw

Modification notes

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 trim panel of cylinder head cover		AR01.20-D-5015NA
2	Remove injection line (8)		AR07.16-D-1080NA
3	Unplug connectors (7) at the injectors (1)
4	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 (6), only replace complete if required.
5	Unscrew stretch bolts (4)	Installation: Always replace stretch bolts (4). Tighten stretch bolts (4) in stages.
			*BA07.16-P-1007-01A
6	Take out clamping claws (3)
7	Pull out injectors (1)	 As of engine end number 445787 mark the installation position when removing the injectors (1), Otherwise the classification must be entered in the engine control unit with the DAS. If injectors (1) are replaced, these must always be classified. If injectors are tight, fit on extraction claw (10) instead of tensioning claw (3) and use together with puller (9) to remove injectors (1).
		Puller	*667589036300
		Extraction claw	*611589013300
		Installation: Install new sealing ring (2). To ensure injection lines (8) are installed free of tension, the injection lines (8) must be fitted on before tightening the injectors (1) and screwed on finger-tight.
8	Clean injectors (1) and injector recesses in cylinder head	 Seal injector recesses with pin before cleaning. Clean injector stems with a suitable brush (brass bristles). Grease injector stems with special grease. Clean injector recesses with a round brush and cylinder brush, blow out and cover over.
		Round brush	*611589006800
		Cylinder brush	*668589006800
		Special grease	*BR00.45-Z-1036-06A
	Notes on injectors		AH07.16-P-1000-01A
		If fuel injectors (Y76) cannot be removed with impact extractor or threaded adapter, see: 
		Remove frozen fuel injectors	AR07.16-D-1000-01A
9	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
10	Inspect fuel system for leaks	 Run engine, switch off and inspect for leaks.

Common rail diesel injection (CDI)

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

611 589 01 33 00

Round brush

Extraction claw

Puller

Cylinder brush

667 589 03 63 00

611 589 00 68 00

668 589 00 68 00

001 589 51 33 00

Hand pump

Hollow piston cylinder

Extraction tool

Hydraulic hose (complete)

611 589 02 33 00

652 589 00 33 21

652 589 00 33 23

Repair materials

Number	Designation	Order number
BR00.45-Z-1036-06A	Special grease	A 001 989 42 51 10

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