REP-TAT-P-1353-01 Remove injector

Preliminary work

Further information is available.

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.

NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe Figure.
Non-observance of these requirements may result in leaks and damage.

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Loosen screws (1).
Release wiring harness from cylinder head cover.

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Loosen screw (1).
Slightly push the clean air pipe (2) to the rear and remove the sound insulation (3) of the high pressure pump.

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Unfasten nut (1).
Detach the wiring harness (2) from the rail.

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To disconnect the connectors on the injectors, it is essential to first pull out lock (1) in the arrow direction.
Press together lock (1) and disconnect connector (2) in the process.

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Unlock connector (1) and disconnect it from the injectors.
Place wiring harness to one side.

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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 the sealing cap (1) onto the oil filler neck.

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To disconnect the connector on the high pressure pump, you must first pull the lock (1) out in the direction of the arrow.
Press together lock (1) in the arrow direction and disconnect the connector in the process

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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: INJECTOR NOZZLES AND LINES
Cleaning the cylinder head in area of injectors if there is 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-protected vacuum cleaner (2) to suck out the dirt particles.
Unlock and disconnect the plug (1).
Release union nuts (2) and (3).

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Remove the high pressure line between the high pressure pump and the rail.

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Unlock the connector and disconnect it from the rail pressure sensor.
Release screws (M5x30) (1).
Remove screws (1).

NOTE: TECHNICAL INFORMATION
Never pull out the screwed combination of injectors and rail from the cylinder head. Remove rail and injectors individually.

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Dispose of screws (1).
Catch and dispose of escaping fuel.
Release screws (M6x70) (1).
Remove screws (1).
Dispose of screws (1).
Remove rail in upward direction.
The injectors remain in the cylinder head.

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If fitted: Remove the gaskets (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.

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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) Stand for the injectors

Unscrew the stands 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.

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If the lever is on the top, the lock (2) is not locked.
Turn the stands (1) by 90° and lock the lock (2) downwards.

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Attach the special tool 2 358 417 to the cylinder head.
Screw in the screws (1) several threads.
NOTE: TECHNICAL INFORMATION
The extraction thread is a left-hand thread.
Fully screw in the pull-out thread (2).

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Slide threaded sleeves (3) in the pull-out thread.
Screw threaded sleeves (3) completely onto the injectors.
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.
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Tighten down screws (4).
TIGHTENING TORQUE SPECIFICATION

Special tool 2 358 417 on cylinder head

5 Nm
Adjust the torque wrench (1) to 13 Nm, clockwise rotation.
Turn the torque wrench (1) in clockwise direction until the injector has been pulled out.

NOTE: TECHNICAL INFORMATION
The injector must be replaced if the torque wrench clicks when the injector is pulled out.

This procedure is absolutely essential for each individual injector.

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Before removing the special tool with the injectors, check whether all injectors were completely pulled out from the cylinder head. This can be recognized by the completely visible threads (1) of the pull-out thread.

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Release the screws and carefully remove the special tool 2 358 417 including the injectors (1) vertically upward from the cylinder head.
Place combination of special tool and injectors down flat on a clean table.

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Unlock the stand lock (1) from the top.

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Turn the unlocked stand (1) 90°; release the injector in a downwards direction and remove.

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