D07.16-1324-09
Shown with engine 642.992 at cylinder 4 |
1 | Injection line | Y76/1 | Injector cylinder 1 | Y76/4 | Cylinder 4 injector | ||
2 | Screw | Y76/2 | Injector cylinder 2 | Y76/5 | Cylinder 5 injector | ||
3 | Clamping claw | Y76/3 | Cylinder 3 injector | Y76/6 | Cylinder 6 injector | ||
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. | |
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. | |
Topical note | Notes on injectors | ||
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | ||
Notes about Common-Rail components | |||
| Remove | ||
1 | Remove injection line (1) of respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | ||
2 | Disconnect electrical connector of respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | ||
3 | Unscrew screw (2) at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | Bolt, clamping claw to injector | |
4 | Remove clamping claw (3) at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | ||
5 | Remove respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | | |
When removing several injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6), mark these assigned to the cylinders. | |||
If one or more injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6) are stuck: | |||
| |||
Remove affected injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | |||
Impact extractor | |||
Threaded adapter | |||
If stuck cylinder 6 injector (Y76/6) will be removed: | |||
| |||
Remove brake booster. | |||
| Clean | ||
6 | Clean respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | ||
7 | Clean injector well at cylinder head of respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6) with a brush. | Round brush | |
Cylinder brush | |||
| Install | ||
8 | Remove sealing ring (4) at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | Replace compression ring (4). | |
9 | Install respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | Observe markings and respective assignment of cylinders during installation of several injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | |
Grease well at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | |||
Special grease | |||
10 | Install clamping claw (3) at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | ||
11 | Screw in screw (2) at respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | Replace screw (2). | |
Bolt, clamping claw to injector | |||
12 | Connect electrical connector of respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | ||
13 | Install injection line (1) of respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | ||
14 | Connect vehicle diagnosis system, read out fault memory, and enter injector classification in the CDI control unit. | When replacing the respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | |
| Connect STAR DIAGNOSIS and read out fault memory | ||
15 | Remove diagnostic system. | When replacing the respective injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6). | |
| Check | ||
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. | |
16 | Check for leaktightness when engine is running. | Visual inspection only. |
668 589 00 68 00
Cylinder brush
642 589 01 33 00
Threaded adapter
355 589 01 63 00
Impact extractor
611 589 00 68 00
Round brush