Remove/install injectors - AR07.16-P-1000T: Notes

ENGINE 646.951 in MODEL 211.004

ENGINE 646.961 in MODEL 211.006 /206 /606

ENGINE 647.961 in MODEL 211.016 /216 /616

ENGINE 648.961 in MODEL 211.023 /026 /223 /226

ENGINE 646.962 in MODEL 203.007 /207 /707

ENGINE 646.963 in MODEL 203.008 /208 /708

ENGINE 646.966 in MODEL 209.308

Fig 1: Identifying Injectors Components - Engine 646.961

Illustrated on engine 646.961

MODIFICATION NOTES

21.2.06

Bolt, tensioning claw to injector

Engine 646.951/961/962/963, 647.961

*BA07.16-P-1004-01D

	Remove/install
	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Risk of explosion from 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 systems when they are under pressure	AS07.16-Z-0001-01A
1	Open engine hood	Model 203	AR88.40-P-1000P
		Model 209	AR88.40-P-1000Q
		Model 211	AR88.40-P-1000T
2	Remove cylinder head cover trim	Engine 646.951/961/962/963, 647.961	AR01.20-P-5014-02A
		Engine 648.961	AR01.20-P-5014-02C
			*BA01.20-P-1002-01G
			*BA01.20-P-1003-01G
3	Disconnect electrical connectors to fuel injectors (Y76)
4	Remove injection lines (1) for common rail diesel injection (CDI)	Counterhold threaded unions (2) when slackening in order to avoid them also being slackened which may result in leaks.	AR07.16-P-1080T
			*BA07.16-P-1007-01D
5	Dismantle leak oil line (4)	For this purpose, press in locking clamps (3) at connections for leak oil line (4) (arrow). Locking clamps (3) remain on fuel injectors (Y76). Installation: Replace removed safety clips (3).
6	Remove clamping claws (5) at fuel injectors (Y76)	If bolt is torn off during removal or thread in cylinder housing is damaged: ↓
		Thread repair for clamping claw mount Installation: Always replace bolts for clamping claws (5). Tighten bolts in stages	AR07.16-P-1000-02A
			*BA07.16-P-1004-01D
			Figure
7	Remove fuel injectors (Y76)	Mark installation location of fuel injectors (Y76). If a fuel injector is tight, (Y76) fit an extraction claw instead of clamping claw (5) and remove fuel injector (Y76) using an extractor.
		The fuel injectors (Y76) can also be removed with the threaded adapter, these fuel injectors (Y76) must then be replaced in all cases. Refer to: ↓	Fig 4
		Remove injectors with threaded adapter	AR07.16-P-1000-01A
			Figure
			Figure
		If fuel injectors (Y76) cannot be removed with extraction claw and puller or thread adapter. Refer to: ↓	Figure
		Remove frozen fuel injectors	AR07.16-P-1000-03B
			Figure
			Figure
			Figure
			Figure
			Figure
		Installation: Replace sealing rings (6). To ensure injection lines (1) are installed free of tension, the injection lines (1) must be fitted on before tightening the fuel injectors (Y76). When installing new injectors (Y76), the control units must be adapted using STAR DIAGNOSIS to store the injector quantity compensation coding in the CDI control unit. Present on the vehicle Make adhesive label unrecognizable according to injector quantity compensation coding.
	Cleaning
8	Clean fuel injectors (Y76) and injector recesses	Close injector recesses before cleaning with a pin to prevent internal damage due to ingress of foreign matter. Clean injector recesses and fuel injectors (Y76) with a wire brush, grease injector recesses using special grease, clean, blow out and cover injector recesses with a round brush and cylinder brush and then clean again using soft cloths to guarantee their trouble-free function. Fuel injectors (Y76) must not be disassembled.
			Fig 2
			Fig 6
		Special grease	*BR00.45-Z-1036-06A
	Notes on injectors		AH07.16-P-1000-01A
9	Install in the reverse order
10	Classify fuel injectors (Y76)	Engine 646 in model 203, 211 with code (803) Model year 2003 Engine 647 in model 211 with code (804) Model year 2004 Engine 648 in model 211 with code (803) Model year 2003 Engine 646 in model 209 Only if a fuel injector (Y76) was exchanged. Refer to: ↓
		Service Information: Injector classification	SI07.16-P-0002A
	Checking
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
11	Check fuel system for leaks with engine running	Carry out visual inspection.
12	Read out fault memory and erase	Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in the fault memories after completing the work.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

CRANKCASE VENTILATION, CYLINDER HEAD COVER

Number	Designation		Engine 646.951/961, 647.961	Engine 646.962/963/966	Engine 648
BA01.20-P-1002-01G	Bolt, cylinder head cover trim to cylinder head	Nm	9	9	9
BA01.20-P-1003-01G	Bolt, cover to charge air manifold.	Nm	9	9	9

COMMON RAIL DIESEL INJECTION (CDI)

Number	Designation			Engine 646.951/ 961, 647.961, 648	Engine 646.962/963/966
BA07.16-P-1004-01D	Bolt, tensioning claw to injector	Stage 1	Nm	7	7
		Stage 2	∠°	90	90
		Stage 3	∠°	90	90
BA07.16-P-1007-01D	Nut, pressure line to rail/injector	Stage 1	Nm	23	23
BA07.16-P-1007-01D	Nut, pressure line to rail/injector	Stage 2	Nm	-	-