Removing the rail with injectors of cylinders 4 to 6

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.

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

Deactivate the 48 v ELECTRICAL SYSTEM .
Disconnect all battery GROUND LEADS .
Remove the hood rear SEAL .
Remove the rear left engine compartment COVER .
Remove the rear right engine compartment COVER .
Remove left and right WIPER ARM .
Remove the cowl COVER .
Remove the ACOUSTIC COVER .
Remove the upper part FIREWALL .
Remove rear ACOUSTIC COVER .
Remove all IGNITION COILS .
Remove 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: RISK OF DAMAGE
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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Release the nuts (1).
Feed out the ground cable (2) and set it aside.
Feed out the cable duct (3) and set it aside.

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Unlock the lock (1) upwards in arrow direction.
Press lock (1) together and release.
Disconnect the connector (2) from the injectors in the direction of the arrow.

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Unlock and release 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: 13 53... Cleaning the cylinder head in area of injectors if there is sandy/dusty contamination
Before releasing the high pressure lines: Blow out the injector shafts with an air gun (1) pressure with little pressure.
Simultaneously, vacuum up the dirt particles with an explosion-proof vacuum cleaner (2).
Release screws (M5x30) (1).
Remove the screws (M5x30) (1).
Do not reuse the screws (M5x30) (1).

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Catch and dispose of leakage fuel with suitable materials.

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Unscrew the screws (M6x30) (arrows).
Remove the screws (M6x30) (arrows).
Do not reuse the screws (M6x30).
Remove the rail (1) upwards.
The injectors remain in the cylinder head.

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Remove the seals (1).
The seals (1) are required during first assembly within the works only 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.
In the event that the specified value for the tensile force is exceeded: Replace injectors.
Use the special tool 2 358 417 to remove the injectors.
Special tool 2 358 417 is used to ensure that the tensile force is not exceeded.

The special tool 2 358 417 consists of:
- (1) Threaded sleeves
- (2) Pull-out thread (left-hand thread)
- (3) Mounting for the injectors
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Unscrew the mount for injectors (1) with the special tool 2 358 417 .

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

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Install all mounts (1) for the injectors.
The mount (1) is not locked if the lever (2) is on the top.

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Turn mounts (1) 90° 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.
Hand-tighten the bolts (arrows).
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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Insert the threaded sleeves (1) again and screw threaded sleeves completely onto the mount for the injectors.
Then tighten screws (arrows) on special tool 2 358 417 to 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.
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.
This can be recognized by the completely visible threads of the threaded 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 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 for one component only. The procedure is identical for all further 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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