Removing the high-pressure rail with injectors of cylinders 1 to 3

WARNING: Working on 12 V electrical system.
Risk of short circuits! Risk of fire!

Make sure that there is no charger connected to the jump start terminal in the engine compartment.
Detach battery ground lead from battery.
For auxiliary batteries: Detach battery minus cables from all auxiliary batteries.

WARNING: Working on fuel system.
Risk of fire! Danger of explosion!

When working on the fuel system, make sure the workstation has sufficient ventilation, e.g., by means of extraction.
Tightly seal off open lines and connections; collect any leakage fuel directly at the point of exit.
No fire, sparks, open flames or smoking.

CAUTION: On releasing high pressure line, fuel may emerge at high speed.
Injury hazard!

Wear suitable personal protective equipment.
Before performing any installation work, allow cooling system to cool down to less than 40°C.
Note warnings on cylinder head cover.

Preliminary work

Refer to DEACTIVATING THE 48 V ELECTRICAL SYSTEM .
Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to RELEASING THE SERVICE OPENING IN SOUND INSULATION ON TOP OF ENGINE .
Refer to REMOVING THE IGNITION COIL .
Refer to REMOVING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .

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: Damage to the ignition coil.
The silicone hose of the ignition coil must not be contaminated by fuel as this can lead to failure of the ignition coil.

When working on the fuel system, cover the ignition coils with suitable materials and remove where required.
Do not oil or grease the silicone tube of the spark plug socket. Do not use any protection or maintenance products (e.g. silicone spray, rubber care products, rust remover, etc.).

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
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.

Prepare special tool 2 413 106.

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Prepare special tool 2 358 417.

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Prepare special tool 2 455 172.

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Prepare special tool 0 496 106 (11 8 720) .

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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 arrow direction.

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Unlock and disconnect all plug connections (1) of the injectors.

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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: CLEANING THE CYLINDER HEAD IN THE AREA OF THE INJECTORS WITH SANDY/DUSTY CONTAMINATION .

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Blow out the injector shafts with slight pressure using air gun (1) before releasing the high pressure lines.
At the same time, use an explosion-proof vacuum cleaner (2) to vacuum the dirt particles.
Unlock plug connection (1) and disconnect.
Release screws (M5x30) (2).
Remove screws (2).
The screws (2) must not be reused.
Catch and dispose of leakage fuel with suitable materials.

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Unscrew the screws (M6x30) (arrows).
Screws must not be reused.
Remove rail (1) in upward direction.
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 injectors.

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Use the special tool 2 358 417 for removing the injectors.
Use special tool 2 358 417 to ensure that tensile force is not exceeded.

The special tool 2 358 417 consists of:
1. Threaded sleeves
2. Pull-out thread (left-hand thread)
3. Mount for the injectors
Unscrew the mount (1) for the injectors from 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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Affix all the mounts (1) for the injectors.
The mount (1) is not locked if the lever (2) is on the top.

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Turn the mounts (1) by 90° in arrow direction and lock the lever (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.

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Hand-tighten the screws (arrows).
The extraction thread is a left-hand thread.
Screw in all the pull-out threads (1) on special tool 2 358 417 fully.

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

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Adjust the torque wrench 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 sleeves (1).
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 upwards from the cylinder head.
Place the combination of the special tool 2 358 417 and the injectors (1) flat onto a clean folding table.

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NOTE: The description is provided only at one component. The procedure is the same for all other components.
Unlock lock (1) of the mount upwards in the arrow direction.

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Turn the unlocked mount (1) by 90° in arrow direction.
Release and remove the injector downwards in arrow direction.

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