Remove/install fuel injectors

AR07.16-D-1020TSV

Remove/install fuel injectors

24.07.2020

Engine

642 in model 907

Modification notes

22.07.2020

Work procedure revised.

The whole document

Shown on right cylinder head on removed engine

1

Fuel injector

3

Screw

5

Sealing ring

2

Electrical connector

4

Clamping claw

 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 injectors

AH07.16-P-1000-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

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

AH00.00-P-0020-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX



Remove

1

Remove high-pressure line of the respective fuel injector (1).

AR07.16-D-1003TSV

2

Disconnect electrical connection (2).

3

Remove screw (3).

 Replace screw/bolt(3).

 Bolt, clamping claw to fuel injector

*BA07.16-N-1001-03TSV

4

Remove clamping claw (4).

5

Remove fuel injector (1).


Store fuel injector (1) upright.
Malfunctions of injectors can otherwise occur.

 When removing several fuel injectors (1), mark these assigned to the cylinders.

 Grease stem of the fuel injector (1).

Special grease

*BR00.45-Z-1036-06A

If one or more fuel injectors (1) are stuck:



Replace affected fuel injectors (1).

AR07.16-S-1000-03SE

 Impact extractor

*355589016300

 Threaded adapter

*642589013300

If the stuck fuel injector (1) of cylinder 6 will be replaced:



Remove brake booster.

AR43.10-D-0350H



Clean

6

Clean fuel injector (1).

7

Clean injector well of fuel injector (1).

 Round brush

*611589006800

 Cylinder brush

*668589006800



Install

8

Remove sealing ring (5).

 Replace sealing ring (5).

9

Install fuel injector (1).

 Observe marking with respective assignment of cylinders during installation of several fuel injectors (1).

 Grease well at fuel injector (1).

Special grease

*BR00.45-Z-1036-06A

10

Install clamping claw (4).

11

Screw in bolt (3).

 Replace screw/bolt(3).

 Bolt, clamping claw to fuel injector

*BA07.16-N-1001-03TSV

12

Connect electrical connector (2).

13

Install high-pressure line of respective fuel injector (1).

AR07.16-D-1003TSV

14

Connect diagnostic device, read out fault memory and enter injector classification in diesel injection system control unit.

When replacing fuel injector (1).



Connect/disconnect diagnostic unit

AD00.00-D-2000-06TS

If existing faults are shown:



Erase the fault memory.

15

Disconnect diagnostic unit.

When replacing fuel injector (1).



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

16

Check for leaktightness when engine is running.

 Visual inspection only.

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 907

BA07.16-N-1001-03TSV

Bolt, clamping claw to fuel injector

Stage 1

Nm

7

Stage 2

°

180

Repair materials

Number

Designation

Order number

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10