Remove/install fuel injectors

AR07.03-G-0004H

12.02.2019

Engine

470.9, 471.9, 473.9 in model 800.310/320

Modification notes

12.09.2018	Note on safety relevant component parts, added.		AH00.00-Z-0019-01A
12.09.2018	Seal top and openings on the fuel injector for cylinders 1 to 6 (Y608 to Y613) with protective covers, added.	Step 9	AR07.03-W-0004-03H
13.09.2018	Notes re the bolted connections which was created according to the torque and angle tightening process, added.		AH00.00-N-0020-01A

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

ENGINE 470.9

8	Electrical line
9	Bracket
10	Air intake line (compressor)

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
 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
 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 threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-N-5000-01H
	Notes on safety-relevant components		AH00.00-Z-0019-01A
	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 expansion reservoir and relieve coolant pressure; then close expansion reservoir again.	 See information from body manufacturer.
2	Remove compressor air intake line (10) from 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, 471.9 as of engine end number 124619, engine 473.9
			AR07.16-G-1008H
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-5016H
6	Remove corresponding fuel high-pressure line of the rail to the fuel injector for cylinders 1 to 6 (Y608 to Y613).		AR07.16-G-1003H
7	Remove fuel lines (2, 4) from the threaded fittings (1, 3).	 Drain fuel residues 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.
		 Box wrench socket	*314589010300
		 Counterholder	*470589000100
8	Mark cylinder 1 to 6 (Y608 to Y613) injection nozzles relative to the respective cylinder.	Only when removing a number of cylinder 1 to 6 (Y608 to Y613) fuel injectors.
9	Remove corresponding fuel injector for cylinders 1 to 6 (Y608 to Y613).		AR07.03-W-0004-03H
		 Do not reuse  protective covers. If reused, contamination may damage the diesel injection system.
		 Extraction tool	*470589013300
		 Set of protective covers	*470589279100
	Install
10	Install new sealing rings on fuel injector for cylinders 1 to 6 (Y608 to Y613).	Only if reusing the fuel injectors for cylinders 1 to 6 (Y608 to Y613).
			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 when installing one or more new fuel injectors for cylinders 1 to 6 (Y608 to Y613).
12	Install corresponding fuel injector for cylinders 1 to 6 (Y608 to Y613) and install new fuel-high-pressure line.		AR07.03-W-0004-04H
		 Always replace removed fuel-high-pressure lines. Leaks may occur otherwise.
		 Assign denoted cylinder 1 to 6 (Y608 to Y613) fuel injectors to the respective cylinders.
		High-temperature grease	*BR00.45-Z-1051-06A
		 Engine 470.9, 471.9, 473.9Bolt, cylinder fuel injector clamping claw to cylinder head	*BA07.16-N-1001-03A
		 Engine 470.9, 471.9, 473.9Connection fitting, high-pressure line to cylinder fuel injector	*BA07.16-N-1002-03A
		 Engine 470.9, 471.9, 473.9Union nut, high-pressure line to rail	*BA07.16-N-1003-03A
		 Engine 470.9, 471.9, 473.9Bolt, high-pressure line cover to camshaft case	*BA07.16-N-1005-03A
		 Ring wrench	*000589070300
		 Box wrench socket	*314589010300
13	Attach fuel lines (2, 4) to the threaded fittings (1, 3).	 Engine 470.9, 471.9, 473.9Union nut, fuel line (nozzle needle valves return) to cylinder head threaded fitting	*BA07.16-N-1019-03A
		 Engine 470.9, 471.9, 473.9Union nut, fuel line (pressure intensifier return) to cylinder head threaded fitting	*BA07.16-N-1021-03A
		 Box wrench socket	*314589010300
14.1	Install wiring harness for fuel injectors for cylinders 1 to 6 (Y608 to Y613).	Engine 470.9 as of engine end number 222434, 471.9 as of engine end number 124619, engine 473.9
			AR07.16-G-1008H
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-5016H
15	Install bracket (9).	Only for engine 470.9
		 Bolt, bracket for resonator to cylinder head/cylinder crankcase	*BA01.30-N-1005-01U
16	Attach compressor air intake line (10) to bracket (9).	Only for engine 470.9
17	Switch on ignition.	Only when installing one or more new fuel injectors for cylinders 1 to 6 (Y608 to Y613).
18	Connect diagnostic system, start XENTRY and perform quick test.	Only when installing one or more new fuel injectors for cylinders 1 to 6 (Y608 to Y613).
		 See information from body manufacturer.
19	Perform injector injection quantity adjustment teach-in process.	Only when installing one or more new fuel injectors for cylinders 1 to 6 (Y608 to Y613).
		 The process is completely menu-assisted under: MCM - engine management (A4)  Adaptations  Parameterization  Adjustment of injector injection quantities
20	End XENTRY and remove the diagnostic system.	Only when installing one or more new fuel injectors for cylinders 1 to 6 (Y608 to Y613).
21	Fill fuel low-pressure circuit on engine.		AR07.16-G-1007H
22	Perform engine test run.	 Allow the engine to run at a higher engine speed.
		If engine fails to start or only runs for a brief period,
		
		Fill fuel low-pressure circuit again.
			AR07.16-G-1007H
23	Check area of the high-pressure lines and fuel lines (2, 4) for leak tightness.	 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