Remove/install injectors

AR07.16-P-1000OLD

Remove/install injectors

18.02.2020

Engine

651 in model 205, 253

6

Leak oil line

22

Fuel injector

A

Leak oil line connection not locked

B

Leak oil line connection locked

Shown on engine 651.911

1

Electrical connector

4

Sealing ring

2

Screw

22

Fuel injector

3

Clamping claw

Shown on engine 651.980

5

Identification plate

22

Fuel injector

 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

Notes about Common-Rail components

AH07.16-P-0002-01TX

 

Remove/install

1

Engine cover; remove thread repair for clamping claw mount

2

Unlock locks for leak oil line connections and detach leak oil line (6) at fuel injectors (22)

 Catch fuel coming out with a lint-free clean dry cloth.

 Installation: Wet the sealing rings for the leak oil line connections with lubricant.

 Observe lock for leak oil line connection: in the locked condition a white marking (arrow) is visible is visible (picture B). The white marking (arrow) is not visible (picture A) in a not locked condition .

Special lubricant

*BR00.45-Z-1055-06A

3

Check sealing rings of the leak oil line connections

If sealing rings are damaged



Replace leak oil line

AR07.03-P-9105CD

4

Release and disconnect electrical connection (1) at fuel injectors (22)

 Installation: Replace sealing rings and housing cover on the electrical connections (1).

 Press safety catch with needle nose pliers together.

5

Remove injection lines between rail and fuel injectors (22)

AR07.16-P-1080OLD

6

Remove screw/bolts (2)

 Installation: Replace screw/bolts (2) and tighten in stages. Determine the difference in height using a  straight edge through simultaneous placing on of the identification plate (5). In this way one can ensure that the fuel injectors (22) are installed correctly. For differences in height of the fuel injectors (22) a sealing ring (4) is missing or there is one sealing ring (4) too many installed.

 Screw/bolt, clamping claw to injector

*BA07.16-P-1005-01H

 Straightedge

*452589019924

7

Check threaded bush and thread on screw/bolts (2)

For a loosened threaded bush or damaged thread



Replace threaded bushes

AR07.16-P-1000-07RF

 Threaded insert for bolt, clamping claw to cylinder head

*BA07.16-P-1010-01H

Mounting adhesive, Loctite 648

*BR00.45-Z-1010-02A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

8

Remove clamping claw (3)

9

Mark fuel injectors (22)

 Installation: in order to assign the fuel injectors (22) to the respective cylinders.

10

Remove fuel injectors (22)


Fuel injectors (22) must not reused when using an impact extractor and must be replaced.
Orderly installation is not guaranteed otherwise.

 Installation: Replace seals (4). Coat stem of the fuel injectors (22) with special grease.

Special grease

*BR00.45-Z-1036-06A

In case of stuck fuel injectors (22)



Remove fuel injectors

AR07.16-P-1000-03CD

 Engine 651 in model 205In case of Bosch injectors
Threaded adapter

*642589013300

 Engine 651 in model 205In case of Delphi injectors
Extraction claw

*651589003300

 Impact extractor

*602589003300

11

Close off connections at fuel injectors (22) with a suitable grommet

 The grommets are available as an replacement part of the fuel injection system; see EPC Group 07. Multiple use of the grommet is not permitted. Ensure scrupulous cleanliness!



Clean

12.1

Clean fuel injectors (22) and fuel injector shafts with a round wire brush

In case of light carbonization.


Clean seat free of residues.
Damage can occur on the cylinder head otherwise.

 Round brush

*651589016800

12.2

Clean fuel injectors (22) and fuel injector wells using a round and cylinder brush

In a case of strong carbonization.


Clean seat free of residues.
Damage can occur on the cylinder head otherwise.

 Round brush

*611589006800

 Cylinder brush

*668589006800

13

Install in the reverse order

14

Connect diagnostic system, read out fault memory and perform a control unit adaptation

For replacement of one or more fuel injectors (22).



AD00.00-P-2000-04B

 For new fuel injectors (22) a control unit adaptation must take place in order to store the "IMA coding" in the CDI control unit. Make adhesive label with respective "IQC coding" illegible on the vehicle.

 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

15

Carry out an engine test run and check fuel injection systems for leaktightness

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1005-01H

Screw/bolt, clamping claw to injector

Stage 1

Nm

15

Stage 2

°

90

Stage 3

°

90

 Common rail diesel injection (CDI)

Number

Designation

Engine 651

BA07.16-P-1010-01H

Threaded insert for bolt, clamping claw to cylinder head

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-02A

Mounting adhesive, Loctite 648

A 003 989 32 71 10

BR00.45-Z-1036-06A

Special grease

A 001 989 42 51 10

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09

BR00.45-Z-1055-06A

Special lubricant

A 000 989 36 60