Removing the rail with injectors of cylinders 4 to 6

Preliminary work

Refer to DEACTIVATING THE 48 V ELECTRICAL SYSTEM .
Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
Refer to REMOVING THE ACOUSTIC COVER .
Refer to REMOVE THE SEAL FOR THE HOOD REAR .
Refer to REMOVING ACOUSTIC COVER AT REAR .
Refer to REMOVING ALL IGNITION COILS
Refer to REMOVE THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL .

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.

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

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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, 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).
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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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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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 replaceed.

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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 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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