Remove/install fuel injectors

AR07.03-P-0004OLI

06.03.2020

Engine

654 in model 205, 253

Modification notes

27.11.2019	Bolt, injector clamping claw to cylinder head		BA07.16-P-1005-04A
14.01.2020	Special tools 270 589 03 91 00 and 355 589 01 63 00 added.

2	Screw
3	Clamping claw
4	Seal
5	Leak oil line
Y76/1	Cylinder 1 fuel injector
Y76/2	Cylinder 2 fuel injector
Y76/3	Cylinder 3 fuel injector
Y76/4	Cylinder 4 fuel injector

P07.16-4445-06

 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
 Warning	Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.	Wear protective gloves, protective clothing and safety glasses, if necessary.	AS00.00-Z-0002-01A
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
	Notes about Common-Rail components		AH07.16-P-0002-01TX
 	Remove/install
1	Remove injection lines.		AR07.16-P-1080OLI
2	Remove leak oil line (5) from fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).		AR07.03-P-9105OLI
3	Remove screws (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, injector clamping claw to cylinder head	*BA07.16-P-1005-04A
4	Clean area around the fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).	Assembly cleaner	*BR00.45-Z-1028-04A
5	Mark fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) relative to the corresponding cylinders.	If the fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) are reused.
6	Remove fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) using clamping claws (3).	 Installation: After removal of fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) using  impact extractor, replace fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4). Replace seals (4). Replace clamping claws (3). Coat injector shafts with special grease. Observe marking if fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) will be reused.
		Special grease	*BR00.45-Z-1036-06A
		 Impact extractor	*355589016300
7	Clean injector wells and seal openings with stop plugs.	 Clean seats without a residue. Damage will otherwise occur on the cylinder head.
		 Plug	*270589039100
		If injector wells are slightly carbonized:
		
		use a round brush.
		 Round brush	*651589016800
		If injector wells are severely carbonized:
		
		use a round brush and a cylinder brush.
		 Round brush	*611589006800
		 Cylinder brush	*668589006800
8	Clean fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).	In case of recycling.
		If fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) are slightly carbonized:
		
		use a round brush.
		 Round brush	*651589016800
		If fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4) are severely carbonized:
		
		use a round brush and a cylinder brush.
		 Round brush	*611589006800
		 Cylinder brush	*668589006800
9	Install in the reverse order.
10	Read out and delete fault memory.
			AD00.00-P-2000-04B
11	Perform control unit adaptation and store injector quantity compensation coding in the CDI control unit (N3/9).	After replacing one or more fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).
			AD00.00-P-2000-04B
12	On the vehicle make an adhesive label with respective "IQC coding" illegible on the vehicle.	After replacing one or more fuel injectors for cylinders 1 to 4 (Y76/1 to Y76/4).