Remove/Install Injectors - Ar07.16-D-1000SF

ENGINE 642.896 /898 /992 /993 in MODEL 906 

Fig 1: Injectors Remove/Install Component Locations

Courtesy of MERCEDES-BENZ USA

Shown on engine 642.992 and injector, cylinder 4 

	Remove/install
	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
	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. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Notes about Common-Rail components		AH07.16-P-0002-01SM
1	Remove injection line (1) for injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6) to be removed		AR07.16-D-1080SF
2	Disconnect electrical connector for injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6) to be removed
3	Remove screw (2) on injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6) to be removed	Installation:  Install new bolt (2).
			*BA07.16-N-1001-01B
4	Remove clamping claw (3) on injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6) to be removed
5	Remove injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6) to be removed	When removing a number of injectors (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6), mark these assigned to the cylinders. Installation:  Grease stem on injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5, Y76/6).
		Special grease	*BR00.45-Z-1036-06A
	Notes on injectors		AH07.16-P-1000-01A
6	Remove sealing ring (4) on removed injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6)	Installation:  Install new sealing ring (4).
	Clean
7	Clean removed injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6)	Only if removed injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6) is not replaced
8	Clean cylinder head of injector well of removed injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6) using a brush		Fig 2
			Fig 3
	Notes on injectors		AH07.16-P-1000-01A
9	Install in the reverse order
10	Connect Star Diagnosis, read out fault memory and enter injector classification in CDI control unit	Only if installing new injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6).
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-D-2000-04SD
	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	Test run engine and check engine in the area of the removed/installed or replaced injector (Y76/1, Y76/2, Y76/3, Y76/4, Y76/5 or Y76/6) for leaks

Fig 2: Identifying Round Brush (611 589 00 68 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Cylinder Brush (668 589 00 68 00)

Courtesy of MERCEDES-BENZ USA