Removing the rail with injectors

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.

NOTE: RISK OF DAMAGE
Damage to battery terminal, the safety battery terminal or the intelligent battery sensor (IBS).
Damaged battery terminals can lead to malfunctions or vehicle electrical system faults.

Detach battery terminal from battery pole by carefully shifting to and fro. Do not pry off using a tool.

Preliminary work

Refer to DEACTIVATING VEHICLE ELECTRICAL SYSTEM .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVING THE REAR HOOD SEAL .
Refer to REMOVING ACOUSTIC COVER AT REAR .
Refer to REMOVING ALL IGNITION COILS .
Refer to REMOVING THE CYLINDER HEAD COVER ACOUSTIC COVER .
Refer to REMOVING 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: NOTES ON ESD PROTECTION (ELECTRO STATIC DISCHARGE) .

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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Prepare special tool 0 490 507 (00 9 170) .

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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.
Unlock and disconnect the plug connection (2) from the injectors.

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NOTE: RISK OF DAMAGE
Damage to wires when disconnecting connectors and plug connections.
Sheared wires can cause a short circuit.

Do not pull on wires when disconnecting connectors and plug connections.

Unlock and disconnect all connectors (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: CLEAN THE CYLINDER HEAD IN THE AREA OF THE INJECTORS WITH SANDY/DUSTY CONTAMINATION .
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.

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Unscrew and remove the screws (M5x30) (1) .
The screws (M5x30) (1) must not be reused.
Replace the bolts (M5x30) (1) .
Parts: Screws (M5x30)
Catch and dispose of leakage fuel with suitable materials.

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Unscrew and remove screws (M6x70) (arrows).
The screws (M6x70) (arrows) must not be reused.
Replace the screws (M6x70) (arrows).
Parts: Screw
Unlock plug connection (1) and disconnect.
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 injectors.

Use special tool 2 358 417 with special tool (spacer sleeves) 2 455 172 to remove the injectors.

With the special tool 2 358 417 and the spacer sleeves 2 455 172 , it is ensured that the tensile force is not exceeded.

The special tool 2 358 417 consists of:

Threaded sleeves
Pull-out thread (left-hand thread)

Mount for the injector

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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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Affix all the mounts (1) for the injectors.
The mounts (1) are not locked if the levers (2) are at the top.

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Turn the mounts (1) in the arrow direction by 90° and lock the levers (2) downward.

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Prepare the panel (1) from the special tool 2 358 417 with the spacer sleeves 2 455 172 .

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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 the special tool 2 358 417 with the spacer sleeves 2 455 172 on the cylinder head.
Hand-tighten the screws (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 the torque wrench (1) with the special tool 0 496 106 (11 8 720) in clockwise direction until the injectors of cylinders 1, 3, 4 are pulled out.
NOTE: TECHNICAL INFORMATION
If the torque wrench makes a crack when the injector is pulled out, the injector must be replaced.
Disassemble all injectors individually.

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Adjust the torque wrench (1) to 13 Nm clockwise rotation .
Turn torque wrench (1) in clockwise direction with special tool 0 490 507 (00 9 170) until the injector of cylinder 2 is pulled out.
NOTE: TECHNICAL INFORMATION
If the torque wrench makes a crack when the injector is pulled out, the injector must be replaced.
Disassemble all injectors individually.

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Before removing the special tool 2 358 417 with the injectors, check if all the injectors were completely pulled out of the cylinder head.
The threads of the pull-out thread must be fully visible.
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 provided only at one component. The procedure is the same for all other components.
Unlock the stand lock (1) from the top.

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

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