Remove/install fuel injectors

AR07.16-S-1020PS

Remove/install fuel injectors

18.04.2019

Engine

642 in model 470, 471

1

Fuel injectors

3

Clamping claw

2

Screw

4

Sealing ring

 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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on injectors

AH07.16-P-1000-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Remove injection lines.

AR07.16-S-1080PS

 Installation: Only install upper engine cover after the leak test.

2

Mark fuel injectors (1) relative to cylinders.

If the fuel injectors (1) are reused.

3

Release and disconnect electrical connectors at fuel injectors (1).

 WIS Service Media
wsm://04_201800_46
Operation steps 3 to 5 are shown on the non-stuck fuel injector (1) of the 5th cylinder.

4

Unscrew bolts (2).

Topical note

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

AH00.00-P-0020-01A

 Installation: Replace screw/bolts (2).

 Bolt, injection nozzle clamping claw to cylinder head

*BA07.16-N-1001-03PS

5

Remove fuel injectors (1) with the clamping claws (3).


Store fuel injectors (1) upright.
Otherwise the fuel injectors (1) will be damaged.

 Installation: Where fuel injectors (1) are reused, observe markings and replace sealing rings (4).

 Installation: Coat wells of fuel injectors (1) with special grease.

Special grease

*BR00.45-Z-1036-06A

If fuel injectors (1) are stuck



Use thread adapter and impact extractor.

 Threaded adapter

*642589013300

 Impact extractor

*602589003300

6

Remove clamping claws (3) from the fuel injectors (1).

7

Clean fuel injectors (1) and fuel injector wells.

If fuel injectors (1) and/or fuel injector wells are severely carbonized



Use round wire brush and cylinder brush.

 Cylinder brush

*668589006800

 Round brush

*611589006800

If fuel injectors (1) and/or fuel injector wells are slightly carbonized



Use round wire brush.

 Round brush

*651589016800

8

Install in the reverse order

9

Read out and delete fault memory.

If a fuel injector (1) or several fuel injectors (1) are being replaced.



AD00.00-S-2000-06P

10

Perform control unit adaptation and store fuel injector quantity compensation coding in diesel injection control unit.

If a fuel injector (1) or several fuel injectors (1) are being replaced.



AD00.00-S-2000-06P

11

Make adhesive label with corresponding fuel injector quantity compensation coding illegible.

If a fuel injector (1) or several fuel injectors (1) are being replaced. If an adhesive label is present.

 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; check the fuel injection system for leaks.

 Common Rail diesel injection system

Number

Designation

Engine 642 in model 470, 471

BA07.16-N-1001-03PS

Bolt, injection nozzle clamping claw to cylinder head

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