Removing the injectors

WARNING: High-voltage system.
The high-voltage system operates on the basis of hazardous, electrical voltage and high currents. Mortal hazard through electric shock!

All work on the high-voltage system may only be carried out by specially trained and technically experienced personnel.
For additional information see:
61 00... SAFETY INSTRUCTIONS ON HANDLING HYBRID CARS
For additional information see:
61 25... NOTES ON REPAIR OF HIGH-VOLTAGE BATTERY UNIT

NOTE: TECHNICAL INFORMATION
With the ignition off and the high-voltage safety plug disconnected, the Check Control message "High voltage system faulty" is displayed by default.
The message "High-voltage system switched off" (absence of voltage) is only displayed when the ignition is switched on.

Preliminary work

Refer to REMOVING THE FLAP IN THE RIGHT-HAND LUGGAGE COMPARTMENT TRIM PANEL .
Refer to DE-ENERGIZING THE HIGH-VOLTAGE SYSTEM .
Refer to CHECKING THAT NO VOLTAGE IS APPLIED .
Refer to DISCONNECTING THE NEGATIVE BATTERY CABLE .
Refer to DISCONNECTING THE NEGATIVE BATTERY CABLE OF THE VEHICLE BATTERY .
Refer to REMOVING THE RIGHT COVER IN THE ENGINE COMPARTMENT .
Refer to REMOVING THE COVER IN THE LEFT ENGINE COMPARTMENT .
Refer to REMOVING TRAILING LINK AT TENSION STRUT TOWER .
Refer to REMOVING THE SOUND INSULATION ON THE BULKHEAD UPPER PART AT THE CENTER .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING CORROSION PROTECTION COVER .
Refer to REMOVING IGNITION COILS .
Refer to REMOVE THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .

NOTE: RISK OF DAMAGE
Damage to injectors.
Excessive force may damage the injector and this means having to replace the injector.

Twist the injectors with a torsional movement of maximum 13 Nm.

NOTE: RISK OF DAMAGE
Damage to the injector tips and Teflon ring.
Improper handling of the injector tips and Teflon ring can lead to malfunctioning of the injector.

Avoid mechanical contact with injector tip.
When exchanging Teflon ring, hands and work surface must be clean and free of oil. Do not use any lubricating agents.
Do not use fingernails to slide Teflon ring on.

NOTE: RISK OF DAMAGE
Contaminant or foreign body.
Contamination can result in malfunctions, loss of function or leaks.

Adhere to the utmost cleanliness.
Protect components from contamination e.g. by covering.
Close off line connections with seal plugs.

NOTE: RISK OF DAMAGE
Electrostatic discharge.
Damage to or destruction of electrical components.

Leave the electrical components in their original packaging until they are being installed. Only use the original packaging for returning the product. Always package removed components straight away.
Read and comply with user information on using the associated special tool 12 7 060.
Only tap the housings of electrical components. Do not tap pins or multi-pin connectors directly.
Wear electrically conductive clothing and antistatic shoes (with ESD symbol).
For additional information see: 61 35... NOTES ON ELECTRO STATIC DISCHARGE PROTECTION

Loosen nut (1).
Feed out ground cable (2) and set it aside.
Feed out cable duct (3) and set it aside.

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Unlock the interlock (1) upwards in arrow direction.
Press lock (1) together and release.
Detach the connector (2) from the injectors in the arrow direction.

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Unlock and release all connectors (1) of the injectors.

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Unscrew the sealing cap (1) from the oil filler neck.

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Dismount the drip shield (1) from the cylinder head cover.

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Screw on the sealing cap (1) onto the oil filler neck.

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NOTE: TECHNICAL INFORMATION
When the vehicle is under dusty/sandy operating conditions, the injector shafts must be cleaned before removing the injectors.
For additional information see: 13 53... CLEANING THE CYLINDER HEAD IN AREA OF INJECTORS IF THERE IS SANDY/DUSTY CONTAMINATION .

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Before releasing the high pressure lines: Use an air gun to blow out the injector shafts (1) with a little pressure.
At the same time, use an explosion-proof vacuum cleaner (2) to vacuum the dirt particles.
Unscrew and remove the screws (M5x30) (1).
Dispose of screws (1).
Replace screws (1).
Parts: Screws (M5x30)
Catch and dispose of leakage fuel with suitable materials.

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Unscrew and remove screws (M6x70) (arrows).
Dispose of the screws (arrows).
Replace the bolts (arrows).
Parts: Screws (M6x70)
Unlock and loosen connector (1).
Remove rail upwards.
The injectors remain in the cylinder head.

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Remove the gaskets (1).
The seals (1) are only required during the initial assembly at the plant and will not be installed again.

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NOTE: RISK OF DAMAGE
Damage to injectors.
Excessive force may damage the injector and this means having to replace the injector.

Twist the injectors with a torsional movement of maximum 13 Nm.

If the predefined value for the tensile force is exceeded, replace the injector.

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Use the special tool 2 358 417 to remove the injectors.
Special tool 2 358 417 ensures that the tensile force is not exceeded.

The special tool 2 358 417 consists of:
- (1) Threaded sleeve
- (2) Pull-out thread (left-hand thread)
- (3) Mount for the injectors
Unscrew the mount for the injectors (1) from the special tool 2 358 417 .

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Press in the lock (1) and remove the threaded sleeve (2) from the special tool 2 358 417 .

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Attach all mounts (1) for the injectors.
The mount (1) is not locked if the lever (2) is on the top.

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Turn mounts (1) by 90° and lock levers (2) downwards.

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NOTE: RISK OF DAMAGE
Damage to injectors.
Excessive force may damage the injector and this means having to replace the injector.

Do not use the puller plate as a support.

Attach special tool 2 358 417 to cylinder head.
Hand-tighten the bolts (arrows).

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NOTE: TECHNICAL INFORMATION
The extraction thread is a left-hand thread.

Screw in pull-out thread (1) on the special tool 2 358 417 fully.

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Slide in threaded sleeves (1) again and screw them fully onto the injector mounts.
Tighten the screws (arrows) on the special tool 2 358 417 to 5 Nm.

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Adjust the torque wrench (1) to 13 Nm clockwise rotation.
Turn torque wrench (1) in clockwise direction with special tool 0 496 106 (11 8 720) until the injector is pulled out.

NOTE: TECHNICAL INFORMATION
If the torque wrench makes a crack when the injector is pulled out, the injector must be replaced.

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Disassemble all injectors individually.
Before removing the special tool 2 358 417 with the injectors, check if all the injectors were completely pulled out of the cylinder head. This can be recognized on the completely visible threads of the pull-out thread.
Loosen screws on special tool 2 358 417 .

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Carefully remove the special tool 2 358 417 with the injectors (1) vertically straight up from the cylinder head.
Place the combination of the special tool 2 358 417 and the injectors (1) flat onto a clean table.

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NOTE: The description is for one component only. The procedure is identical for all further components.

Unlock the stand lock (1) from the top.

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Turn the unlocked stand (1) by 90°.
Release and remove the injector downwards.

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