Removing and installing/replacing all injectors (S55 engine)

Special tools required: 

• 0 496 885
• 00 9 170
• 13 0 190
• 13 0 280

Disconnect NEGATIVE BATTERY TERMINAL (risk of fire due to short-circuiting on dismantling).

Electric fuel pump starts up automatically when door is opened!

Carry out installation work on fuel system only with coolant temperature below 40°C.

Fuel can emerge spontaneously at high speed when the high pressure line is released!

Oil and dirt particles may get into your eyes!

Before removing the rail and the injectors, clean or draw off the injector shafts.

Recycling: 

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Introduced contaminants can cause malfunctions in the system!

• Do not allow any dirt particles or foreign bodies to get into the system.
• Remove all traces of dirt contamination before removing lines or separate components.
• Use only lint-free cloths.
• Seal all fuel system openings with protective caps or plugs.

The resistance of the silicone material is reduced significantly by contact with fuel, which may cause the ignition coil to fail!

When assembling, it is essential to adhere to screwing sequences and tightening torques!

Not adhering to the disassembly and installation instructions can lead to cracked weld seams and can thus cause an engine fire!!! 

Necessary preliminary work: 

• Disconnect NEGATIVE BATTERY TERMINAL (risk of fire due to short-circuiting on dismantling).
• Remove RAIL .

Removal: 

Unlock connector (1) from injectors and detach. Slacken nut (2).

Remove ground cable (3).

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Otherwise, the hold-down device may tilt.

Remove holding-down element (3).

Pull injectors upward out of cylinder head and remove.

Mark injectors.

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Procedure in event of stuck injector: 

Use special tool 0 496 885 to remove injectors that are stuck.

Lightly oil pull-out thread (1) and unscrew completely (see illustration) before using the special tool.

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Fit special tool 0 496 885 on injector shaft. Join screws (1) to injector slot by a few threads. Screw in pull-out thread (2) until it is possible to screw the threaded sleeves (3) onto the injectors. Screw threaded sleeves (3) onto injectors and tighten down.

Tighten screws (1).

Tightening torque 13 53 6AZ .

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Fit torque wrench (1) and special tool 00 9 170 on hexagon head (2) of special tool 0 496 885.

Turn torque wrench (1) in clockwise direction until the injector is pulled out.

After removing the injector (2), seal the injector tip and fuel line connection with protective caps (1).

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Installation note: 

When installing a new injector:

• Replace decoupling element (1).

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Installation note: 

When reusing fuel injector:

• Replace decoupling element (1).
• Replace Teflon ring (2).

A Teflon ring that has already been installed once in the cylinder head must be replaced before the injector is reinstalled.

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Replace Teflon ring: 

Before replacing the Teflon ring (1), make sure your hands and the work surface are clean and free of oil.

Avoid mechanical contact with injector tip (2).

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Remove Teflon ring (2) using special tool (3) 13 0 191 from the set of special tools 13 0 190 from the injector (1).

Use a fluff-free cloth only to remove combustion residues from cylindrical part of injector tip (do not use ultrasound or other tools/agents).

Do not clean injector tip.

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Push new Teflon ring (1) onto installation cone (2) 13 0 283 from the set of special tools 13 0280.

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Mount Teflon ring (1) with installation cone (2) 13 0 283 onto injector tip (3).

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Using special tool (1) 13 0 281 from set of special tools 13 0 280, push Teflon ring (2) into groove (3) on the injector.

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To adjust the widened Teflon ring to the installation dimension, special tool (1) 13 0 282 from set of special tools 13 0 280 must be slid up to limit position on injector (2).

Do not use any lubricating agents.

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Installing injector: 

Before installing injector in engines that have been run: 

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The injector must be replaced if this value is exceeded!

• Check injector bore for dirt.

Clean only dirty  injector bores.

• Clean injector bore: To do so, preferably slide injector without decoupling element (1) but with new Teflon ring (2) in and out of injector bores several times.

The Teflon ring must subsequently be replaced.

• Clean contact surfaces of decoupling elements (1) in cylinder head.
• Replace decoupling element (1).

An injection quantity compensation must be carried out if an injector is replaced or changed on the cylinder side.

Injection quantity compensation is carried out with the aid of a so-called adjustment value.

Additional information regarding the injection quantity compensation can be found at the end of the repair instructions.

Insert injectors in injector bores.

Position special tool 0 496 885 onto the injector shaft. Join screws (1) to injector slot by a few threads. Screw in the pull-out thread (2) until the threaded sleeves (3) can be screwed onto the injectors. Screw threaded sleeves (3) onto injectors and tighten down.

Tighten screws (1).

Tightening torque 13 53 6AZ .

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Fit torque wrench (1) and special tool (2) 00 9 170 on hexagon head (2) of special tool 0 496 885.

Turn torque wrench (1) in counterclockwise direction until 2 Nm are reached.

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Installation note: 

Install hold-down device (1) with curvatures (black arrows) downward.

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Installation: 

Fit hold-down device (3) on injectors.

Fit screws (1) hand-tight.

Only fit the screw (2) loosely to prevent the hold - down device from tilting.

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First tighten screw (1).

Tightening torque 13 53 6AZ .

Then tighten screw (2).

Tightening torque 13 53 6AZ .

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Feed in ground cable (3) and install.

Tighten nut (2).

Tightening torque 13 53 6AZ Connect and lock injector connectors (1).

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Reset ultra-small quantity adaptation: 

• Connect diagnosis system and follow the diagnosis instructions. 
• Read out vehicle data
• Identification without vehicle test
• Start vehicle test
• Vehicle handling
• Service functions
• Power train
• Engine electronics
• Adjustment functions
• Delete adaptations
• Reset adaptation values
• Resetting minimum quantity adaptations

Required follow-up work: 

• Install RAIL .

Clean spark plug slot.

Assemble engine.

Check fuel system for leak tightness.

Check function of DME.