Removing rail of cylinders 4 to 6

WARNING: Hot fluids.
Risk of scalding!

Conduct all work in the vehicle wearing appropriate personal protective equipment only.

Preliminary work

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 REMOVE IGNITION COILS .
Refer to REMOVE THE HIGH PRESSURE LINE BETWEEN THE RAIL AND THE HIGH PRESSURE PUMP .

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.
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 the arrow direction.
Press lock (1) together and release.
Detach the connector (2) from the injectors in the arrow direction.
Unlock and release all the connectors (1) of the injectors.

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Release screws (M5x30) (1).
Remove the screws (M5x30) (1).

The screws (M5x30) (1) must not be reused.

Catch and dispose of leakage fuel with suitable materials.

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Unscrew the screws (M6x30) (arrows).
Remove the screws (M6x30) (arrows). The screws (M6x30) must not be reused.
Remove rail (1) in upward direction.

The injectors remain in the cylinder head.

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Remove the seals (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.

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If 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 ensures 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) Mount for the injectors

Unscrew the mount for injectors (1) from the special tool 2 358 417 .

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Press in the lock (1) and remove the threaded sleeve (2) from the special tool 2 358 417.

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Affix all the injector mounts (1).

The mount (1) is not locked if the lever (2) is on the top.

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Turn the mounts (1) by 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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Slide in the threaded sleeves (1) again and screw them fully onto the injector mounts.
Then, tighten the screws (arrows) on the 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.
Disassemble all injectors individually.

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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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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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