Remove/Install Injectors - AR07.16-P-1000CD

ENGINE 651 in MODEL 166, 172, 204, 207, 212, 218, 221 

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

Courtesy of MERCEDES-BENZ USA

	Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.	No parts of the body or limbs should be within the operating area when the components are moving.	AS00.00-Z-0011-01A
	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
	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 contact with 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
	Notes on injectors		AH07.16-P-1000-01A
	Remove/install
1	Remove top engine cover
2	Disconnect leak oil line (6)	Installation:  Wet the sealing rings for the leak oil connections using special lubricant. Observe lock for leak oil line connection: in the locked condition a white marking is visible (picture B). In a not  locked condition the white marking is not visible  (picture A). Special lubricant	*BR00.45-Z-1055-06A
3	Remove injection lines between rail and fuel injectors (Y76)		AR07.16-P-1080CD
4	Release and disconnect electrical connections (1) on fuel injectors (Y76)	Installation:  Replace sealing rings and housing cover on the electrical connections (1). To this do press safety catch with needle nose pliers together.
5	Remove screw/bolts (2)	Installation:  Replace screw/bolts (2). Tighten screw/bolts (2) in stages. Determine the difference in height using a straight edge through simultaneous placing on of the identification plate (5). In this way one can ensure that the fuel injectors (Y76) are installed correctly. For differences in height of the fuel injectors (Y76) a sealing ring (4) is missing or there is a sealing ring (4) too many installed. Screw/bolt, clamping claw to injector	*BA07.16-P-1005-01H
		Straightedge	Fig 6
6	Check threaded sleeve and thread on screw/bolts (2)	Installation:  Apply adhesive thinly and apply evenly to the new threaded bushing. Then screw this in to collar and caulk with a center punch mark. Installation:  Allow adhesive material to cure for at least 6 h. Only install after curing of the injection nozzle. For a loosened threaded sleeve or damaged thread ↓ Remove threaded sleeves and blow out thread in cylinder head, clean and replace the threaded sleeve.	*BR00.45-Z-1046-04A
		Loctite 7063 cleaning spray (150 ml) Mounting adhesive, Loctite 648	*BR00.45-Z-1010-02A
		Threaded insert for bolt securing clamping claw to cylinder head	*BA07.16-P-1010-01H
7	Remove clamping claw (3)
8	Mark fuel injectors (Y76) in order to assign the fuel injectors (Y76) to the respective cylinders.
9	Remove fuel injectors (Y76)	Fuel injectors (Y76) must not reused when using an impact extractor and must be replaced. Orderly installation is not guaranteed otherwise.	*BR00.45-Z-1036-06A
		Installation:  Replace sealing rings (4). Coat fuel injectors (Y76) with special grease. Special grease	Fig 4
		ENGINE 651 in MODEL 166, 172, 204, 207, 212, 218, 221 For Bosch injectors Threaded adapter	Fig 1
		ENGINE 651 in MODEL 166, 172, 204, 207, 212, 218, 221 For Delphi injectors Extraction claw	Fig 2
		Impact extractor In case of jammed fuel injectors (Y76): ↓ Remove jammed fuel injectors.	AR07.16-P-1000-03CD
10	Seal openings in the cylinder head using suitable stop plugs	These are obtainable as a ET for the injection system. Repeated usage of stop plugs is not allowed. Ensure scrupulous cleanliness!
	Clean
11.1	Clean fuel injectors (Y76) and injector wells with a round brush	In case of light carbonization. Clean seat free of residues. Damage can occur on the cylinder head otherwise. Round brush	Fig 7
11.2	Clean fuel injectors (Y76) and injector wells using a round and cylinder brush	In a case of strong carbonization. Clean seat free of residues. Damage can occur on the cylinder head otherwise. Cylinder brush	Fig 3
		Round brush	Fig 5
12	Install in the reverse order.
13	Connect diagnostic system and perform a control unit adaptation, read out fault memory and clear it if necessary	When replacing fuel injectors (Y76). For new fuel injectors (Y76) a control unit adaptation must take place over the diagnostic system in order to store the "IQC coding" in the CDI control unit. Make adhesive label with respective "IQC coding" illegible on the vehicle.	AD00.00-P-2000-04A
14	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. Check fuel system for leaks with engine 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. Carry out visual inspection.	AS00.00-Z-0005-01A

Fig 1: Identifying Extraction Claw (651 589 00 33 00)

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Fig 2: Identifying Impact Extractor (602 589 00 33 00)

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

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Fig 4: Identifying Threaded Adapter (642 589 01 33 00)

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Fig 5: Identifying Round Brush (611 589 00 68 00)

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Fig 6: Identifying Straightedge (452 589 01 99 24)

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Fig 7: Identifying Round Brush (651 589 01 68 00)

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