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

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ENGINES 642 in MODEL 207, 212, 218, 221 

Fig 1: Injectors Remove/Install Components
G09974672Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER 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
1 Remove injection lines (21/6)   AR07.16-P-1080SXI 
2 Disconnect electrical connectors (1) at fuel injectors (Y76)    
3 Remove bolts (5) TORQUE SPECIFICATION *BA07.16-P-1006-01C 
4 Remove clamping claw (6)    
5 Remove fuel injectors (Y76) IMPORTANT Mark fuel injectors (Y76) to position fuel injectors (Y76) at original points when installing
INSTALLATION IMPORTANT Replace bolts (5) and sealing rings (7). Coat fuel injectors (Y76) with special grease.
When installing new injectors (Y76), a control unit adaptation must take place using STAR DIAGNOSIS in order to store the injector quantity compensation coding in the CDI control unit (N3/9). Deface the injector quantity compensation coding on the adhesive label on the vehicle.		 AD00.00-P-2000-04A
    SPECIAL TOOL Impact extractor Figure
    SPECIAL TOOL Thread adapter Figure
    Special grease *BR00.45-Z-1036-06A 
NOTES Notes on injectors   AH07.16-P-1000-01A
CLEAN Clean     
6 Clean fuel injectors (Y76) and fuel injector shafts in cylinder head SPECIAL TOOL Round brush Figure
    SPECIAL TOOL Cylinder brush Figure
NOTES Notes on injectors   AH07.16-P-1000-01A
7 Install in the reverse order    
DANGER 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
8 Check fuel system for leaks with engine running    
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 ∠ ° 0
Fig 2: Identifying Round Brush (611 589 00 68 00)
G09974673Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Cylinder Brush (668 589 00 68 00)
G09974674Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Impact Extractor (602 589 00 33 00)
G09974675Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Threaded Adapter (642 589 01 33 00)
G09974676Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

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