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

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Disconnect plug connection (1) and detach 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 plug connection to the high pressure pump, it is essential to first pull out lock (1) in the arrow direction.
Press lock (1) together in the arrow direction and disconnect the plug connection 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: CLEAN THE CYLINDER HEAD in the area of the injectors with sandy/dusty contamination

Blow out the injector shafts with slight pressure using air gun (1) before releasing the high pressure lines. At the same time, use an explosion-proof vacuum cleaner (2) to suction the dirt particles.
Unlock plug connection (1) and disconnect.
Release union nuts (2) and (3).

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

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

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Unlock plug connection (2) and detach it from the rail pressure sensor.

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

Release, remove and dispose of the screws (M5x30) (1).
Catch and dispose of escaping fuel.

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Release, remove and dispose of the screws (M6x70) (1).
Remove rail in upward direction.
The injectors remain in the cylinder head.

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NOTE: The following step(s) must be performed if the listed component(s) is/are installed.

Remove 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.

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 the following parts:
- (1) Threaded sleeves
- (2) Pull-out thread (left-hand thread)
- (3) Stand for the injectors
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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.
If the lever is on the top, the lock (2) is not locked.

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Turn the mounts (1) 90° and lock the locking mechanisms (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

5Nm
Adjust the torque wrench (1) to 13 Nm, clockwise rotation.
Turn torque wrench in clockwise direction until the injector is 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 combination of special tool and 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 combination of special tool 2 358 417 and injectors (1) vertically upward from the cylinder head.
Place the combination of the special tool and the injectors flat onto a clean table.

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Unlock lock (1) of the mount upwards in the arrow direction.

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Turn the unlocked mount (1) by 90° in the arrow direction.
Release and remove the injector downwards in the arrow direction.

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