Installing the injectors for the cylinders 1 to 4

Preparing the injectors for installation

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: TECHNICAL INFORMATION
Before re-exchanging the injector, the Teflon ring must be replaced. Once a Teflon ring has been installed, it may not be re-used. New injectors are supplied with a new Teflon ring.
After installation of a new Teflon ring on the injectors, the injector must be installed in the cylinder head within 10 minutes or protected with protective caps; otherwise, the Teflon ring will swell.

Before installing the injectors: Replace the Teflon rings (1).
Parts: Teflon rings
Avoid mechanical contact with injector tip (2).

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Remove Teflon ring (1) by using special tool 2 452 959 from injector (2).
If necessary, use a lint-free cloth to clean the cylindrical part of the injector tip. Do not use ultrasonic sound or other auxiliary materials.
Do not clean injector tip.

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For installing the new Teflon ring: Use 2 448 401 set of special tools:
1. Installation cone
2. Sliding sleeve
3. Assembly sleeve
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Slide Teflon ring (1) onto installation cone (2) from the set of special tools 2 448 401 .

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Ensure correct installation position of the assembly sleeve (1) from the set of special tools 2 448 401 :
The larger diameter of the assembly sleeve (1) must point to the injector tip.

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Ensure correct installation position of the assembly sleeve (1) from the set of special tools 2 448 401 :
The assembly sleeve (1) is not mounted correctly if the smaller diameter points to the injector tip.

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Mount the Teflon ring (2) with the installation cone (1) from the set of special tools 2 448 401 on the injector tip.

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Slide the Teflon ring (2) by using the sliding sleeve (1) from the set of special tools 2 448 401 in arrow direction into the groove (3) on the injector.

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Feed out and remove the sliding sleeve (1) from the set of special tools 2 448 401 in arrow direction.

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Feed out and remove the installation cone (1) from the set of special tools 2 448 401 in arrow direction.

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Make sure that the widened Teflon ring (1) is placed clean in the groove (2) of the injector (3) and can be easily moved with fingers.

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Calibrate the widened Teflon ring with the assembly sleeve (1) from the set of special tools 2 448 401 in arrow direction to the installation dimension.
Make rotational movements in increments of 180° synchronous to the detaching movement. While doing so, move slowly and not using a jerking motion.
This calibrates Teflon ring (1) to the installation dimension.
Guide out and remove assembly sleeve (1).

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Check if the installation dimension of the Teflon ring (1) is correct:
1. Shows that the Teflon ring has the correct installation dimension.
2. Shows that the Teflon ring does not have the correct installation dimension.

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Install injectors

NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe screwing sequences and tightening torques.
Failure to comply with the regulations can lead to leaks and damage.

NOTE: The description is provided only at one component. The procedure is the same for all other components.

Retrofit foam jacket on cylinders 5-8, replace if necessary (not required for cylinders 1-4)

NOTE: The description is provided only at one component. The procedure is the same for all other components.

Check

Check if foam jacket (2) is installed on injector (1).

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Result

» Foam jacket (2) is not installed.

Measure

Retrofit foam jacket (2) as described in the following step.

Parts: Foam jacket

Result

» Foam jacket (2) is installed.

Measure

Replace foam jacket (2) as described in the following step.

Parts: Foam jacket

Position foam jacket (1) in the recess of the injector in area (2).

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Mount the injectors (1) on the special tool (2) 2 410 777.
Align the plug connections of injectors (1) in the correct installation position.

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Insert the injectors in the injector bore holes with special tool (1) 2 410 777.
Screw in the screws (2) and (3) on the injector shaft with a few thread starts.
Check, if the pull-out thread (4) and the threaded sleeves (5) are correctly mounted.
Tighten screws (2) and (3).

TIGHTENING TORQUES SPECIFICATION

Special tool 2 410 777 to injector well
M6	tightening torque	8 Nm

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Adjust the torque wrench (1) to 2 Nm, counter-clockwise.
Position the torque wrench (1) and special tool (2) 0 496 106 (11 8 720) on the hexagon head of special tool 2 410 777 .
Turn the torque wrench (1) in anti-clockwise direction until 2 Nm apply.
Remove special tool 2 410 777 .

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Install hold-down device (1) with curvatures (see arrow) downwards.

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Mount the hold-down device (2) on the injectors.
Screw in the screw (1) by a few turns only.

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