Remove/install injectors - AR07.16-P-1000TI

ENGINE 642 in MODEL 211 

Fig 1: Identifying Injector Components

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

20.2.06

Bolt, tensioning claw to injector

*BA07.16-P-1006-01C

	Remove/install
	Risk of death  caused by contact with parts conducting high voltages.	Do not touch parts which conduct high voltages. Persons with electronic implants (e.g. cardiac pacemaker) must never work on piezo injectors.	AS07.16-Z-0002-01A
	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
	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 the system when it is pressurized.	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. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	Notes on injectors		AH07.16-P-1000-01A
1	Remove injection lines (21/6)		AR07.16-P-1080TI
2	Disconnect electrical connectors (1) at fuel injectors (Y76)
3	Remove screws (5)	Screw of clamping claw to injector	*BA07.16-P-1006-01C
4	Remove clamping claw (6)
5	Remove fuel injectors (Y76)	Installation:  replace bolts (5) and sealing rings (7). Coat fuel injectors (Y76) with special grease. Mark fuel injectors (Y76) to position fuel injectors (Y76) at original points when installing When installing new injectors (Y76), control units must be adapted using STAR DIAGNOSIS to store injector quantity compensation coding in CDI control unit (N3/9). Present in the vehicle Make the adhesive label unrecognizable according to injector quantity compensation coding.
		Impact extractor	Fig 4
		Thread adapter	Fig 5
		Special grease	*BR00.45-Z-1036-06A
	Clean
6	Clean fuel injectors (Y76) and fuel injector shafts in cylinder head	To avoid damage always observe notes for injectors.
		Round brush	Fig 2
		Cylinder brush	Fig 3
7	Install in the reverse order
8	Run engine and inspect fuel system for leaks

COMMON RAIL DIESEL INJECTION (CDI)

Number	Designation			Engine 642
BA07.16-P-1006-01C	Bolt, tensioning claw to injector	Stage 1	Nm	7
		Stage 2	∠°	90
		Stage 3	∠°	90

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Impact Extractor (602 589 00 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Threaded Adapter (642 589 01 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1036-06A	Special grease	A 001 989 42 51 10