Remove/Install Fuel Injectors - AR07.16-P-1000OGR

ENGINE 642 in model 166, 292 

Fig 1: Fuel Injectors Components Location - Engine 642 In Model 166

Courtesy of MERCEDES-BENZ USA

Shown on model 166 

	Risk of death  when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.	AS00.00-Z-0035-01A
	Remove/install
1	Remove respective injection line (21/6) of the fuel injector (Y76) to be removed		AR07.16-P-1080OGR
2	Disconnect electrical connection (1) of the fuel injector (Y76) to be removed
3	Remove covers over suspension strut towers and the left as well as the right section of the bulkhead	When using the impact extractor in combination with the thread adapter for the removal of jammed fuel injectors (Y76) on the 2, 3, 5 and 6 cylinder Impact extractor	Fig 3
		Threaded adapter	Fig 4
4	Remove water drain duct on the left suspension strut tower	When using the impact extractor in combination with the thread adapter for removal of the jammed fuel injectors (Y76) on cylinder 6
5	Remove right air duct segment in ventilation box of the dust filter	When using the impact extractor in combination with the thread adapter for removal of the jammed fuel injectors (Y76) on cylinder 3
6	Remove screw/bolt (4) on fuel injector (Y76) to be removed	Bolt, clamping claw to injector	*BA07.16-P-1006-01C
7	Remove clamping claw (5) on fuel injector (Y76) to be removed
8	Remove fuel injector (Y76) to be removed
Courtesy of MERCEDES-BENZ USA	Notes on injectors	Use the impact extractor and thread adapter in a case of a jammed fuel injector (Y76).	AH07.16-P-1000-01A
		When removing a number of fuel injectors (Y76) is the assignment to the respective fuel injector shaft should be marked. : Replace screw/bolts (4) and sealing ring (6). Coat fuel injector (Y76) with special grease. Special grease	*BR00.45-Z-1036-06A
		Impact extractor	Fig 3
		Threaded adapter	Fig 4
	Clean
9	Clean removed fuel injector (Y76)	In case of reusability
10	Clean fuel injector shaft on cylinder head	Round brush	Fig 5
Courtesy of MERCEDES-BENZ USA	Notes on injectors		AH07.16-P-1000-01A
		Cylinder brush	Fig 2
11	Install in the reverse order
12.1	Store quantity differential coding in the CDI control unit (N3/9), read out the fault memory and clear if necessary	When replacing fuel injectors (Y76)
		Deface the injector quantity compensation coding on the adhesive label on the vehicle.	AD00.00-P-2000-04A
12.2	Connect diagnostic system, read out fault memory and delete if necessary	When reusing the fuel injectors (Y76)
			AD00.00-P-2000-04A
	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.	AS00.00-Z-0005-01A
13	Check fuel system for leaks with ENGINE running

COMMON RAIL DIESEL INJECTION SYSTEM (CDI)

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

Fig 2: Identifying Cylinder Brush (668 589 00 68 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Impact Extractor (602 589 00 33 00)

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

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

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

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