Remove/install injectors

AR07.16-D-1000R

Remove/install injectors

15.08.2019

Engine

646 in model 909

Modification notes

18.12.2013

Checking the installation height of the injector, added

AH07.16-P-1000-01S

1

Injection line

5

Clamping claw

Y76/2

Injector cylinder 2

2

Leak oil line

B6/19

Rpm sensor

Y76/3

Cylinder 3 injector

3

Electrical connector

Y76/1

Injector cylinder 1

Y76/4

Cylinder 4 injector

4

Screw

 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

Topical note

Notes on injectors

AH07.16-P-1000-01S

 

Remove/install

1

Remove injection line (1)

AR07.16-D-1080R

2

Detach leak oil line (2) at cylinder 1 to 4 injectors (Y76/1, Y76/2, Y76/3, Y76/4) and place to one side

AR07.03-D-9105R

3

Detach electrical connectors (3)

4

Disconnect electrical connection on rpm sensor (B6/19)

5

Remove bolts (4)

 Installation: Replace screws/bolts (4).

 Bolt, clamping claw to fuel injector

*BA07.16-N-1003-01A

6

Remove clamping claws (5)

7

Remove cylinder 1 to 4 injectors (Y76/1, Y76/2, Y76/3, Y76/4)

 Installation: Install new sealing rings. Coat injector shafts with special grease. To ensure injection lines (1) are installed free of stress during mounting, the injection lines (1) must be attached before tightening to the cylinder 1 to 4 injectors (Y76/1, Y76/2, Y76/3, Y76/4).

 When removing the cylinder 1 to 4 injectors (Y76/1, Y76/2, Y76/3, Y76/4), mark the sequence otherwise the injector classification must be entered again into the CDI control unit using the diagnostic system.

Special grease

*BR00.45-Z-1036-06A

For firmly jammed cylinder 1 to 4 injectors (Y76/1, Y76/2, Y76/3, Y76/4), see:



Remove cylinder 1 to 4 injectors (Y76/1, Y76/2, Y76/3, Y76/4)

AR07.16-D-1000-03WF

 Adapter plate

*668589013200

 Upright

*611589002300

 Hand pump

*652589003321

 Extraction claw

*640589003300

 Hollow piston cylinder

*001589513300

8

Clean cylinder 1 to 4 injectors (Y76/1, Y76/2, Y76/3, Y76/4) and injector wells

 After cleaning close off openings with  stop plugs.

 Cylinder brush

*668589006800

 Round brush

*611589006800

 Brake caliper brush

*000589266800

 Record plug

*129589009100

9

Install in the reverse order

10

Enter injector classification into the CDI control unit

When replacing the cylinder 1 to 4 injectors (Y76/1, Y76/2, Y76/3, Y76/4



AD00.00-D-2000-04F

11

Connect diagnostic system; read out fault memory.



AD00.00-D-2000-04F

 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

12

Perform an engine test run, switch off the engine and check leaktightness of the fuel system and cylinder 1 to 4 injectors (Y76/1, Y76/2, Y76/3, Y76/4)

 Common rail diesel injection (CDI)

Number

Designation

Engine 646.7 in model 909

BA07.16-N-1003-01A

Bolt, clamping claw to fuel injector

Stage 1

Nm

7

Stage 2

°

180

Stage 3

°

-

Repair materials

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10