Remove/install fuel injectors

AR07.16-S-1020EA

Remove/install fuel injectors

06.03.2020

Engine

654.9 in model 447

Modification notes

27.11.2019

Bolt, injector clamping claw to cylinder head

BA07.16-P-1005-04A

1

Fuel injector

2

Screw

3

Clamping claw

4

Seal

 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 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 the injection line on the corresponding cylinder.

AR07.16-S-1080EA

2

Remove the leak oil line from the fuel injector (1).

AR07.03-S-9105EA

3

Remove screw/bolt (2).

Topical note

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

AH00.00-P-0020-01A

 Installation: Replace screw/bolt (2).

 Bolt, injector clamping claw to cylinder head

*BA07.16-P-1005-04A

4

Clean the area around the fuel injector (1).

Assembly cleaner

*BR00.45-Z-1028-04A

5

Mark the fuel injector (1) relative to the corresponding cylinder.

If the fuel injector is reused (1).

6

Remove the fuel injector (1) with the associated clamping claw (3).

 Installation: If the fuel injector (1) is removed with an  impact extractor, the fuel injector (1) must be replaced.
Install new seal (4).
Install new clamping claw (3).
Coat the injector shaft with special grease.

Special grease

*BR00.45-Z-1036-06A

If the fuel injector (1) is stuck,



remove the fuel injector (1) with an impact extractor.

Remove/install air/water duct

AR83.25-S-1410E

 To remove the fuel injector (1) from cylinders 2 and 3, the air–water duct must be removed.

 Impact extractor

*355589016300

7

Clean the fuel injector (1) and injector well.

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

If the fuel injector (1) / injector well are carbonized,



use a round brush and a cylinder brush.

 Round brush

*611589006800

 Cylinder brush

*668589006800

8

Install in the reverse order.

9

Read out and delete fault memory.



AD00.00-S-2000-04E

10

perform control unit adaptation and save the injector quantity comparison coding in the diesel injection system control unit.

For replacement of one or more fuel injectors (1).



AD00.00-S-2000-04E

11

Make the existing adhesive label with respective injector injection quantity adjustment coding illegible on the vehicle.

For replacement of one or more fuel injectors (1).

 Common rail diesel injection system

Number

Designation

Engine 654

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