Remove high-pressure rail
Preliminary work
- Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
- Refer to REMOVING REAR HOOD SEAL .
- Refer to REMOVING FRONT WINDSHIELD PANEL COVER .
- Refer to REMOVING SUSPENSION CROSS-BRACE .
- Refer to REMOVING THE UPPER BULKHEAD COVER PANEL .
- Refer to REMOVING THE ACOUSTIC COVER .
- Refer to IF INSTALLED: PARTIALLY REMOVING THE ENGINE VENTILATION LINE .
- Refer to REMOVING IGNITION COILS .
- Refer to REMOVE THE HIGH PRESSURE LINE BETWEEN THE RAIL AND THE HIGH PRESSURE PUMP .
NOTE:
RISK OF DAMAGE
Damage to injectors.
Excessive force may damage the injector and this means having to replace the injector.
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:
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.
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
Contaminant or foreign body.
Contamination can result in malfunctions, loss of function or leaks.
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
Electrostatic discharge.
Damage to or destruction of electrical components.
Electrostatic discharge.
Damage to or destruction of electrical components.
- Leave the electrical components in their original packaging until they are being installed. Only use the original packaging for returning the product. Always package removed components straight away.
- Read and comply with user information on using the associated special tool 12 7 060.
- Only tap the housings of electrical components. Do not tap pins or multi-pin connectors directly.
- Wear electrically conductive clothing and antistatic shoes (with ESD symbol).
- For additional information see: 61 35... NOTES ON ESD (ELECTROSTATIC DISCHARGE) PROTECTION
- Unlock and loosen connector (1).
- Unlock and loosen connector (2).
- Unlock the locks (arrows).
- Feed out cable duct (3) and set it aside.
- Loosen screw (1).
- Loosen nut (2).
- Feed out ground cable (3) and set it aside.
- Slightly raise the wiring harness section (4) for the injectors and the ignition coils.
- Close openings with the special tool 2 413 106.
NOTE:
RISK OF DAMAGE
Damage to wires when disconnecting connectors and plug connections.
Sheared wires can cause a short circuit.
Damage to wires when disconnecting connectors and plug connections.
Sheared wires can cause a short circuit.
- Do not pull on wires when disconnecting connectors and plug connections.
- Unlock the interlock (1) upwards in arrow direction.
- Press lock (1) together and release.
- Detach the connector (2) from the injector in arrow direction.
- Unlock and release all connectors (1) of the injectors.
- Feed out the wiring harness section (2) for the injectors and ignition coils and put to one side.
- Unlock and release plug connection (1).
- Loosen union nut (1).
- Catch and dispose of escaping fuel.
- Loosen screws (2).
- Guide the fuel feed line (3) out and set it aside.
- Make sure the rubber damper (4) does not get lost.
- Close openings with the special tool 2 413 106.
- Loosen screws (1).
- Loosen screws (1).
- Feed rail (1) out to the top and remove it.
- Catch and dispose of escaping fuel.
- Guide out and remove gaskets (1).
The seals (1) are only required during the initial assembly at the plant and will not be installed again.
NOTE:
RISK OF DAMAGE
Damage to injectors.
Excessive force may damage the injector and this means having to replace the injector.
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.
- If the predefined value for the tensile force is exceeded, replace the injector.
- Use special tool 2 358 417 with special tool (spacer sleeves) 2 455 172
to remove the injectors.
With the special tools 2 358 417 and the spacer sleeves 2 455 172 it is ensured that the tensile force is not exceeded.
The special tool 2 358 417 consists of:
- (1) Threaded sleeve
- (2) Pull-out thread (left-hand thread)
- (3) Mount for the injectors
- Unscrew the mount for injectors (1) from special tool 2 358 417.
- Press in lock (1) and remove threaded sleeve (2) from special tool 2 358 417.
- Attach all fixtures (1) from the special tool 2 358 417 to the injectors.
Mount (1) is not locked if the lever (2) is on the top.
- Turn the mounts (1) 90° in arrow direction and lock the lever (2) downwards.
- Prepare the panel (1) from the special tool 2 358 417 with the spacer sleeves 2 455 172 .
NOTE:
RISK OF DAMAGE
Damage to injectors.
Excessive force may damage the injector and this means having to replace the injector.
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 panel (1) from the special tool 2 358 417 with the spacer sleeves 2 455 172 on cylinder head.
- Hand-tighten the bolts (arrows).
NOTE:
TECHNICAL INFORMATION
The extraction thread is a left-hand thread.
The extraction thread is a left-hand thread.
- Completely screw in the pull-out thread (1) on the panel (2) of the special tool 2 358 417.
- Unlock the locks (1).
- Insert threaded sleeves (2) in arrow direction.
- Screw threaded sleeves (1) onto the injectors in arrow direction.
- Make sure that threaded sleeves (1) are fully in contact with the pull-out thread (2).
- Ensure that locks (1) engage audibly.
- Tighten screws (arrows) on the panel (1) of the special tools 2 358 417
.TIGHTENING TORQUES SPECIFICATION
Special tool for injectors to cylinder head Special tool Tightening torque 5Nm
NOTE:
TECHNICAL INFORMATION
If the torque wrench makes a crack when the injector is pulled out, the injector must be replaced.
If the torque wrench makes a crack when the injector is pulled out, the injector must be replaced.
- Adjust the torque wrench (1) to 13 Nm clockwise.
- Turn torque wrench (1) in clockwise direction with special tool 0 496 106 (11 8 720) until the injector is pulled out.
- 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. You can tell this is the case by the completely visible threads (1) of the pullout thread.
- Detach screws (arrows) on the panel (1) with special tool 2 358 417.
- Carefully remove the special tool 2 358 417 with the injectors vertically straight up from the cylinder head.
- Place the combination of the special tool 2 358 417 and the injectors 2 455 172 with the spacer sleeves (1) flat onto a clean table.
NOTE:
The description is provided only at one component. The procedure is the same for all other components.
- Unlock the stand lock (1) from the top.
- Turn the unlocked stand (1) by 90° .
- Release and remove the injector downwards.