13 53 318 Removing and installing/replacing all injectors (B46, B48)

Special tools required: 

• 2 358 417
• 130 190
• 13 0 280
• 2 358 022

Attention! 

Wear full face guard and protective gloves.

Fuel can emerge spontaneously at high speed when the high pressure line is released!

Attention! 

Wear safety goggles.

Oil and dirt particles may get into your eyes!

Before removing the rail and the injectors, clean or draw off the injector shafts.

Recycling: 

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Attention! 

Adhere to conditions of absolute cleanliness when carrying out repair work on the high-pressure fuel system!

Introduced contaminants can cause malfunctions in the system!

• Do not allow any dirt particles or foreign bodies to get into the system.
• Remove all traces of dirt contamination before removing lines or separate components.
• Use only lint-free cloths.
• Seal all fuel system openings with protective caps or plugs.

Attention! 

Ignition coils must not be fouled by fuel.

The resistance of the silicone material is reduced significantly by contact with fuel, which may cause the ignition coil to fail!

Observe the repair instruction for cleaning the cylinder head in the area of injectors to prevent sand/dust contamination!

Attention! 

When assembling, it is essential to adhere to screwing sequences and tightening torques!

Not adhering to the disassembly and installation instructions can lead to cracked weld seams and can thus cause an engine fire!!! 

Necessary preliminary work: 

• Remove ACOUSTIC COVER 
• Remove INTAKE FILTER HOUSING 
• Remove STRUT BRACE
• Remove IGNITION COILS

Removal: 

Release screws (1).

Release wiring harness from cylinder head cover.

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Release screw (1).

Slightly push clean air pipe (2) to the rear and remove the sound insulation (3) of the high pressure pump.

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Slacken nut (1).

Detach the wiring harness from the rail.

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Release connector (1) and remove from the injectors.

Lay wiring harness to one side.

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Unscrew the sealing cap (1) of 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) to the oil filler neck.

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Before loosening the high pressure rail: Blow out the injector shafts with an air gun (1) with less pressure.

Simultaneously, draw off the dirt particles with an explosion proof vacuum cleaner (2).

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Unlock connector (1) and remove.

Release union nuts (2) and (3).

Remove pressure line between high pressure pump and rail.

Catch and dispose of escaping fuel.

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Attention! 

Not adhering to the disassembly instructions can lead to cracked weld seams and can thus cause an engine fire!!! 

Unlock connector from rail pressure sensor and pull off.

Release screws (1) M5x30.

Remove screws (1).

Do not disassemble the tightly screwed combination from the injectors with the rail from the cylinder head! 

Screws (1) must not  be reused! Parts:  Screws M 5x30.

Catch and dispose of escaping fuel with suitable materials.

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Release screws (1) M6x70.

Remove screws (1). Screws (1) must not  be reused!

Parts:  Screws M6x70.

Remove rail upwards.

Injectors remain in the cylinder head.

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If fitted: 

Remove gaskets (1).

Gaskets (1) are not  required and will not  be installed any more!

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Injectors may be twisted to a maximum of 13 N.m with a torsional movement.

The special tool 2 358 417 is required in order to remove the injectors.

Using the special tool 2 358 417 ensures that the tensile force is not exceeded.

Special tool 2 358 417 consists of:

• (1) Threaded sleeves
• (2) Pull-out thread (left-hand thread)
• (3) Fixture for injector

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Unscrew fixture for injectors (1) from special tool 2 358 417.

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

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Install all fixtures (1) for the injectors.

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Rotate the mounting (1) at 90° and latch the lock (2) downwards.

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Attach special tool 2 358 417 to cylinder head.

Tighten screws (1) hand-tight.

Screw in pull-out thread (2) completely.

The pull-out thread (2) is a left-hand thread. 

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Insert threaded sleeves (3) again and screw threaded sleeves completely onto the fixtures for injectors.

Then tighten the screws (4) with 5 N.m.

Attention! 

Do not support on the panel of the extraction tool. Impermissible lateral forces can occur from this on the injectors.

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Adjust torque wrench to 13 N.m clockwise rotation.

Turn torque wrench in clockwise direction until the injector is pulled out.

This process is obligatorily to be carried out for every single injector.

Attention! 

The injector must be replaced if the torque wrench clicks when the injector is pulled out.

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Before removing the special tool with the injectors check, whether all injectors were completely removed from the cylinder head. This can be recognized on the completely visible threads of the brass tubes.

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Loosen the screws and carefully remove the drive-out tool 2 358 417 including injectors (1) from the cylinder head vertically towards the top.

Take off the combination of the special tool with injectors flatly on a clean table.

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Unlatch the lock (1) of the fixture upwards.

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Rotate the unlocked fixture (1) at 90°. Release and remove the injector downwards.

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Preparation for installation: 

Replace Teflon ring: 

Before the injectors are installed, the Teflon rings (1) at the injectors must be replaced.

Part:  Teflon rings.

Before replacing the Teflon ring (1), make sure your hands and the work surface are clean and free of oil.

Avoid mechanical contact with injector tip (2).

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Remove Teflon ring (2) using special tool (3) 13 0 191 from the set of special tools 13 0 190 from the injector (1).

Use a fluff-free cloth only to remove combustion residues from cylindrical part of injector tip (do not use ultrasound or other tools/agents).

Do not clean injector tip.

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Push new Teflon ring (1) onto installation cone (2) 13 0 283 from the set of special tools 13 0 280.

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Fit Teflon ring (1) on injector tip (3) with installation cone (2) 13 0 283 from set of special tools 13 0 280.

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Use special tool (1) 13 0 281 from set of special tools 13 0 280 to slide Teflon ring into groove (3) on injector.

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To bring the widened Teflon ring to the installation dimension, special tool (1) 13 0 282 from set of special tools 13 0 280 must be slid up to limit position on injector (2).

Do not use any lubricating agents.

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Attention! 

Injection quantity compensation!

An injection quantity compensation must be carried out if an injector is replaced or changed on the cylinder side.

Injection quantity compensation is carried out with the aid of a so-called adjustment value.

Additional information regarding the injection quantity compensation can be found at the end of the repair instructions.

Installation: 

Attention! 

Not adhering to the installation instructions can lead to cracked weld seams and can thus cause an engine fire!!! 

Mount retaining bridge (1) via bayonet fitting (2) to injector.

If fitted: 

If the retaining bridge (1) is equipped with a cast lug, the correct installation position needs to be observed.

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Retaining bridge mounted properly  , cast lug is at rear.

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Retaining bridge mounted improperly  , cast lug (1) is at front.

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Distance gauge (1) 2 358 022.

Not using the gauge may present the risk of cracking weld seams at the injector! 

The thickness of the distance gauge is 8.5 millimeter. If the actual value drops below this dimension, the distance gauge needs to be replaced.

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Mount injectors with retaining bridges and new  screws (M5x30) to the rail.

Keep the rail on a clean table in such a way, that the holders on the Rail are visible upwards. The electrical injector connections must then lie to the left of the holders of the rail.

Slide the distance gauge (2) 2 358 022 between retaining bridge and rail on top of the injector head.

Make sure the distance gauge rests against the retaining bridge!

Equally tighten both injector screws (1) M5x30 by hand until the distance gauge rests plane against the rail and the retaining bridge.

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Then the distance gauge (1) 2 358 022 is to be removed again.

Repeat this operation for all injectors.

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Check injectors for loose fit at the rail.

Align connectors of the injectors roughly parallel to the rail, injectors need to be freely movable!

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1. Position rail with injectors from the top on the cylinder head.
   1. Make sure the injector tips catch the corresponding holes in the cylinder head.
   2. Make sure the alignment lugs of the injector are properly inserted into the retaining holes on the cylinder head.
2. As soon as a resistance can be felt when pushing down, position the rail screws M6x70 (A) and (B) and tighten them hand-tight.
3. Tighten rail screws (A) and (B) alternating in every 180° steps, until the rail rests against the cylinder head (see the illustration below).
4. Insert rail screws (C) and (D).
5. Tighten rail screws in the following order by 5 N.m: 

1. Tighten screw (A) by 5 N.m.
2. Tighten screw (D) by 5 N.m.
3. Tighten screw (B) by 5 N.m.
4. Tighten screw (C) by 5 N.m.

Rail (1) is fully in contact with the cylinder head.

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1. Now tighten injector screws M5x30 in pairs (1 with 2, 3 with 4, 5 with 6, 7 with 8) and in alternating order for 90° hand-tight, using the socket on the extension (without reversible ratchet or torque wrench!). 
2. Screw the injector screws M5x30 according to the following plan:

   Set torque wrench to 5 N.m. 

   Compliance with the sequence is absolutely mandatory!

   • Fuel injector 1: 
     1. Tighten injector screw (1) by 90±15° with torque wrench.
     2. Tighten injector screw (2) by 90±15° with torque wrench.
     3. Repeat steps  a and  b until both screws have arrived at 5 N.m.
   • Fuel injector 2: 
     1. Tighten injector screw (3) by 90±15° with torque wrench.
     2. Tighten injector screw (4) by 90±15° with torque wrench.
     3. Repeat steps  a and  b until both screws have arrived at 5 N.m.
   • Fuel injector 3: 
     1. Tighten injector screw (5) by 90±15° with torque wrench.
     2. Tighten injector screw (6) by 90±15° with torque wrench.
     3. Repeat steps  a and  b until both screws have arrived at 5 N.m.
   • Fuel injector 4: 
     1. Tighten injector screw (7) by 90±15° with torque wrench.
     2. Tighten injector screw (8) by 90±15° with torque wrench.
     3. Repeat steps  a and  b until both screws have arrived at 5 N.m.
   Fig 2: Injector Screws Tightening Sequence

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3. All injector screws (1) to (8) must be marked by a line (see illustration).
   • Tighten injector screws with an angle of rotation! 
     1. Tighten injector screw (1) with an angle of rotation of 90±15°.
     2. Tighten injector screw (2) with an angle of rotation of 90±15°.
     3. Tighten injector screw (3) with an angle of rotation of 90±15°.
     4. Tighten injector screw (4) with an angle of rotation of 90±15°.
     5. Tighten injector screw (5) with an angle of rotation of 90±15°.
     6. Tighten injector screw (6) with an angle of rotation of 90±15°.
     7. Tighten injector screw (7) with an angle of rotation of 90±15°.
     8. Tighten injector screw (8) with an angle of rotation of 90±15°.
   Fig 3: Injector Screws Tightening Sequence

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4. Check whether all injector screws (1) to (8) have been tightened with an angle of rotation of 90°.

   All marks (dashes) must lie diagonally (see illustration).

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5. Release rail screws M6x70 (A), (B), (C), (D) (Releasing procedure is mandatory!  ).

   After that, tighten rail screws again in the following order by 5 N.m: 

   1. Tighten screw (A) by 5 N.m.
   2. Tighten screw (D) by 5 N.m.
   3. Tighten screw (B) by 5 N.m.
   4. Tighten screw (C) by 5 N.m.

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6. All rail screws (A) to (D) must be marked by a dash (see illustration).

   Tighten rail screws M6x70 (A), (B), (C), (D) with an angle of rotation of 90±15°.

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7. Check whether all rail screws (A) to (D) were tightened by an angle of rotation of 90°.

   All marks (dashes) must lie diagonally (see illustration).

Mount high pressure line at the rail first, then mount high pressure line at the high pressure pump.

First, tighten union nuts (3) on the rail hand-tight.

Then, tighten union nut (2) on the high pressure pump hand-tight.

Tighten union nuts (3) and (2) to tightening torque.

Tightening torque 33±2 N.m.

Attach connector (1) to high-pressure pump.

Connector (1) must engage audibly.

Connect connector on the high pressure pump until the lock (1) engages audibly.

Then lock the lock (1) in the direction of the arrow.

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Connect connector (1) to the injectors.

Connectors (1) must engage audibly.

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Connect connector on the injectors until the lock (1) engages audibly.

Then lock the lock (1) in the direction of the arrow.

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Mount wiring harness (1) on rail.

Tighten nut (1).

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Install sound insulation (3).

Fit clean air pipe (2).

Tighten screw (1).

Tightening torque: 13 71 6AZ .

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Install wiring harness on cylinder head cover.

Tighten screws (1).

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

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Mount the drip shield (1) on the cylinder head cover.

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

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Required follow-up work: 

• Install INTAKE SILENCER HOUSING 
• Install ACOUSTIC COVER 
• Installing the IGNITION COILS
• Install the STRUT BRACE
• Connect BATTERY EARTH LEAD

Attention! 

If a solenoid injector was replaced or replaced on the cylinder side, the ultra small quantity adaptation must be reset. Reset ultra-small quantity adaptation: 

• Connect diagnosis system and follow the diagnosis instructions. 
• Read out vehicle data
• Identification without vehicle test
• Start vehicle test
• Vehicle handling
• Service functions
• Power train
• Engine electronics
• Reset adaptation values
• Adaptation values of fuel system
• Continue service function