Remove/install fuel injectors · ar0703g0004n · Mercedes-Benz WIS

AR07.03-G-0004N

Remove/install fuel injectors

12.02.2019

Engine

470.9, 471.9 in model 800.110/112

Modification notes

08.09.2018

Work procedure completely revised.

W07.16-1085-09

Shown on engine 471.9

1	Threaded fitting	6	Clip	Y611	Cylinder 4 fuel injector
2	Fuel line	7	Bracket	Y612	Cylinder 5 fuel injector
3	Threaded fitting	Y608	Cylinder 1 fuel injector	Y613	Cylinder 6 fuel injector
4	Fuel line	Y609	Cylinder 2 fuel injector
5	Clamps	Y610	Cylinder 3 fuel injector

Shown on engine 470.9

8	Electrical line
9	Bracket
10	Compressor air intake duct

W07.03-1064-06

 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-0001-01B
 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
 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
 Warning	Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-N-5000-01H
	Note on calculation of tightening torque when using insertion or socket tools with various effective lengths		AH00.00-P-0015-01CW
	Remove
1	Open cap on coolant expansion reservoir and relieve coolant pressure; then close expansion reservoir again.	 See information from body manufacturer.
2	Remove compressor air intake line (10) on bracket (9).	Only for engine 470.9
3	Remove bracket (9).	Only for engine 470.9
4	Clean engine in the area of the fuel lines (2, 4).
5.1	Remove wiring harness of the fuel injectors for cylinders 1 to 6 (Y608 to Y613).	Engine 470.9 as of engine end number 222434, engine 471.9 as of engine end number 124619,
			AR07.16-G-1008N
5.2	Remove intermediate frame under cylinder head cover.	Engine 470.9 up to engine end number 222433, 471.9 up to engine end number 124618
			AR01.20-G-5016N
6	Remove corresponding high-pressure line of the rail to the fuel injector for cylinders 1 to 6 (Y608 to Y613).		AR07.16-G-1003N
7	Remove fuel lines (2, 4) from the threaded fittings (1, 3).	 Remove the fuel lines (2, 4) in order to allow running of a residual fuel amount from the cylinder head. When unfastening fuel lines (2, 4) counterhold the threaded fitting (1, 3) on cylinder head with the  counterholder. Damage can occur otherwise due to a fluid lock of the engine or then unfastening the fuel lines (2, 4).
		 Collect fuel which runs out in a suitable container.
		 Counterholder	*470589000100
		 Box wrench socket	*314589010300
8	Mark cylinder 1 to 6 (Y608 to Y613) injection nozzles relative to the respective cylinder.	Only for removal of a number of fuel injectors.
9	Remove corresponding fuel injector for cylinders 1 to 6 (Y608 to Y613).		AR07.03-W-0004-03H
		 Extraction tool	*470589013300
		 Set of protective covers	*470589279100
	Install
10	Install new sealing rings on fuel injectors for cylinders 1 to 6 (Y608 to Y613).	Only when reinstalling removed fuel injectors.
			AR07.03-W-0004-01H
		High-temperature grease	*BR00.45-Z-1051-06A
		 Puller tool	*470589043300
11	Mark coding of all fuel injectors for cylinders 1 to 6 (Y608 to Y613) relative to the respective cylinder.	Only for replacement of one or more fuel injectors.
12	Install respective fuel injector for cylinders 1 to 6 (Y608 to Y613) and new high-pressure lines.		AR07.03-W-0004-04H
		 The removed high-pressure lines must always be replaced. Leaks may occur otherwise.
		 Assign marked fuel injectors for cylinders 1 to 6 (Y608 to Y613) to the corresponding cylinders.
		 Engine 470.9, 471.9Bolt, cylinder fuel injector clamping claw to cylinder head	*BA07.16-N-1001-03A
		 Engine 470.9, 471.9Connection fitting, high-pressure line to cylinder fuel injector	*BA07.16-N-1002-03A
		 Engine 470.9, 471.9Union nut, high-pressure line to rail	*BA07.16-N-1003-03A
		 Engine 470.9, 471.9Bolt, high-pressure line cover to camshaft case	*BA07.16-N-1005-03A
		High-temperature grease	*BR00.45-Z-1051-06A
		 Box wrench socket	*314589010300
		 Ring wrench	*000589070300
		 Torque wrench	*001589662100
		 Open end wrench attachment, 19_mm	*000589109919
13	Attach fuel lines (2, 4) to the threaded fittings (1, 3).	 Engine 470.9, 471.9Union nut, fuel line (pressure intensifier return) to cylinder head threaded fitting	*BA07.16-N-1021-03A
		 Engine 470.9, 471.9Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting	*BA07.16-N-1019-03A
		 Box wrench socket	*314589010300
14.1	Install wiring harness of the fuel injectors for cylinders 1 to 6 (Y608 to Y613).	Engine 470.9 as of engine end number 222434, engine 471.9 as of engine end number 124619,
			AR07.16-G-1008N
14.2	Install intermediate frame under cylinder head cover.	Engine 470.9 up to engine end number 222433, 471.9 up to engine end number 124618
			AR01.20-G-5016N
15	Install bracket (9).	Only for engine 470.9
		 Bolt, bracket for resonator to cylinder head/cylinder crankcase	*BA01.30-N-1005-01U
16	Install compressor air intake line (10) on bracket (9).	Only for engine 470.9
17	Switch on ignition.	Only if new fuel injectors were installed.
		 See information from body manufacturer.
18	Connect vehicle diagnosis system, start diagnosis and perform quick test.	Only if new fuel injectors were installed.
		 See information from body manufacturer.
19	Perform injector injection quantity adjustment teach-in process.	Only if new fuel injectors were installed.
		 The process is completely menu-assisted under: MCM - engine management (A4)  Adaptations  Parameterization  Adjustment of injector injection quantities
20	End diagnosis and remove vehicle diagnosis system.	Only if new fuel injectors were installed.
21	Fill fuel low-pressure circuit on engine.		AR07.16-G-1007N
22	Start engine and perform an engine test run.	 Allow the engine to run at a higher engine speed. See information from body manufacturer.
		If engine fails to start or only runs for a brief period,
		
		Fill fuel low-pressure circuit again.
			AR07.16-G-1007N
23	Stop engine and check area of the high-pressure lines and fuel lines (2, 4) for leaks.	 Visual inspection.

 Cylinder head

Number	Designation		Engine 470.9
BA01.30-N-1005-01U	Bolt, bracket for resonator to cylinder head/cylinder crankcase	Nm	25