Removing the rail with injectors of cylinders 1 to 3

WARNING: High-voltage system .
The high-voltage system operates on the basis of hazardous, electrical voltage and high currents. Mortal hazard through electric shock!

All work on the high-voltage system may only be carried out by specially trained and technically experienced personnel.
For additional information see:
SAFETY INSTRUCTIONS ON HANDLING HYBRID CARS .
For additional information see:
NOTES ON REPAIR OF HIGH-VOLTAGE BATTERY UNIT .

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.

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.

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

Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to RELEASING THE SERVICE OPENING IN SOUND INSULATION ON TOP OF ENGINE .
Refer to REMOVING ALL IGNITION COILS .
Refer to 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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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 lock (1) arrow direction from the top.
Press lock (1) together and release.
Detach the connector (2) from the injectors.

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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: CLEANING THE CYLINDER HEAD IN THE AREA OF THE INJECTORS WITH SANDY/DUSTY CONTAMINATION .

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Before releasing the high pressure lines: Blow out the injector shafts with an air gun (1) pressure with little pressure.
Simultaneously, suction up the dirt particles with an explosion-proof vacuum cleaner (2).
Unlock and loosen connector (1).
Release screws (M5x30) (2).
Remove screws (2).
Do not reuse the bolts (2).

Parts: Screws (M5x30)
Catch and dispose of leakage fuel with suitable materials.

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Unscrew the screws (M6x30) (arrows).
The screws may not be reused!
Replace screws.
Parts: Screws (M6x30)
Remove the rail (1) in upward direction.
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.

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.

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 stand for the injectors (1) from 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 stands (1) for the injectors.
The intake (1) is not locked if the lever (2) is on the top.

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Turn intakes (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).

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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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Insert threaded sleeves (1) again and screw threaded sleeves completely onto the stands for 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 .

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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.
This can be recognized on the completely visible threads of the sleeves (1).
Loosen screws on special tool 2 358 417 .

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Remove the special tool 2 358 417 with injectors (1) carefully upwards vertically from the cylinder head.
Place the combination of the special tool 2 358 417 and the injectors (1) flat on 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 stand (1) by 90°.
Release and remove the injector downwards.

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