Remove/install injectors · ar0716d1000nb · Mercedes-Benz WIS

AR07.16-D-1000NB

Remove/install injectors

6.2.07

ENGINE 647.981 in MODELS WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7

ENGINE 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada

ENGINE 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA

ENGINE 647.981 in MODELS 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico

D07.16-1246-06

1 Injector

2 Injector sealing ring

3 Clamping claw

4 Bolt

5  Puller

6  Extraction claw

7 Leak oil line

8 Connector

9 Injection line

Modification notes

19.12.06

Bolt, tensioning claw to injector

Engine 647.981

*BA07.16-N-1003-01A

	Remove/install
Danger!	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Pour fuels only 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-5015NB
2	Remove injection line (9)		AR07.16-D-1080NB
3	Unplug connectors (8) at injectors (1)
4	Press safety clamps for injectors (1) onto the closed side all the way (arrow), remove leak oil line (7) and place aside	 Do not disassemble leak oil line (7), only replace complete if required.
5	Remove bolts (4) on clamping claw (3)	Installation: Always replace bolts (4). Tighten bolts (4) in stages.
			*BA07.16-N-1003-01A
6	Take out clamping claws (3)
7	Pull out injectors (1)	 Identify the installation sequence, Otherwise the classification must be entered in the engine control unit with STAR DIAGNOSIS. If injectors (1) are replaced, these must always be classified. If injectors are stuck (1):  fit on extraction claw (6) instead of the clamping claw (3) and remove injector (1) with injector sealing ring (2) using the puller (5).
		Puller	*667589036300
		Extraction claw	*611589013300
		Installation: To ensure the injection lines (9) are installed free of tension, the injection lines (9) must be fitted on before tightening the fuel injectors (1).
	Notes on injectors		AH07.16-P-1000-01A
8	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 sealing rings (2).
		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: 
		Removing jammed 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 engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch 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 647.981


BA07.16-N-1003-01A	Bolt, tensioning claw to injector	Stage 1	Nm	7
		Stage 2	°	180
		Stage 3	°	-

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

Repair materials

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

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

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