Remove high-pressure rail

Preliminary work 

• Refer to DEACTIVATING ELECTRICAL SYSTEM .
• Refer to REMOVING THE SEAL FOR THE HOOD REAR .
• Refer to REMOVING THE COVER OF THE ENGINE COMPARTMENT AT THE REAR LEFT .
• Refer to REMOVING THE COVER OF THE REAR RIGHT ENGINE COMPARTMENT .
• Refer to REMOVING LEFT AND RIGHT WIPER ARM .
• Refer to REMOVING THE COWL COVER .
• Refer to REMOVING THE FIREWALL UPPER PART .
• Refer to REMOVING THE ACOUSTIC COVER .
• Refer to REMOVING ACOUSTIC COVER AT REAR .
• Refer to REMOVING 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 .

• 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 connector (2) from the injectors.

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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: CLEAN THE CYLINDER HEAD IN THE AREA OF THE INJECTORS WITH 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).

  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:  Screws (M6x70)

• 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.

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• Use the special tool 2 358 417 to remove 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 injector
• 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 mounts (1) are not locked if the levers (2) are up.

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

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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.

  The thread starts 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 stand (1) by 90°. 
• Release and remove the injector downwards.

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