Install injectors

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NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe screwing sequences and tightening torques.
Failure to comply with the regulations can lead to leaks and damage.

Mount the holder (1) via the bayonet fitting (2) on the injector.
If the holder (1) has a cast lug: Ensure that the installation position of the holder is correct.

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If necessary, note the position of the cast lug:
The holder is mounted correctly when the cast lug lies in the rear.

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If necessary, note the position of the cast lug:
The holder is mounted incorrectly when cast lug (1) lies in the front.

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NOTE: RISK OF DAMAGE
Damage to injectors .
Weld seams on the injector may tear due to incorrect distances between the rail and injector so that the injector must be replaced .

Insertion of the distance gauge is compulsory.
Replace distance gauge, if a thickness of 8.5 mm is no longer given in the distance gauge.

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Use the special tool (distance gauge) 2 358 022 (1).
Replace the bolts (1) (M5x30).
Parts: Screws (M5x30)
Mount the injectors with the holders and the new screws (1) (M5x30) on the rail.
Place the rail on a clean table so that the openings for the injectors on the rail point upwards.
The electrical injector connections must point towards the fuel pressure sensor.
Slide the special tool (distance gauge) 2 358 022 (2) between the holders and the rail onto the injector head.

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Make sure that the special tool (distance gauge) 2 358 022 (2) rests flat on the retaining bridge .
Tighten both the screws (1) (M5x30) evenly by hand until the special tool (distance gauge) 2 358 022 (2) rests flat against the rail and the holder.
Remove the special tool (distance gauge)2 358 022 (1).
Repeat this operation for all injectors.

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Check injectors for loose fit at the rail.
Align the position of the electrical injector connections parallel to the rail.
The injectors must be able to move freely.

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Attach the rail (1) with the injectors to the cylinder head from the top.
Ensure that the injector tips hit the bores provided in the cylinder head for the injection in the cylinder head.
Ensure that the guides on the injector are slid correctly into the guide bore holes in the cylinder head.
Push the rail (1) down until a resistance can be felt.

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Replace the screws (A), (B), (C) and (D) (M6x70).
Parts: Screws (M6x70)
Position the new screws (A), (B), (C) and (D) (M6x70) and hand-tighten them.
Set torque wrench to 2 Nm.
Apply the screws (A), (D), (B) and (C) in alternating order in 90° steps.
If the tightening torque of (2 Nm) is reached before the rail (1) is on the cylinder head (2) lie: Disassemble the rail (1) and repeat the installation procedure.

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NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe screwing sequences and tightening torques.
Failure to comply with the regulations can lead to leaks and damage.

Tighten bolt (A) with 5 Nm.
Tighten bolt (D) with 5 Nm.
Tighten bolt (B) with 5 Nm.
Tighten bolt (C) with 5 Nm.

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NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe screwing sequences and tightening torques.
Failure to comply with the regulations can lead to leaks and damage.

Fig 1: Fuel Injector Rail Bolts Tightening Sequence

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Attach a socket to an extension.
Do not use a reversible ratchet or torque wrench.
Tighten the bolts (M5x30) in pairs in 90° increments hand-tight. Observe the following sequence: (1) with (2), (3) with (4), (5) with (6) and (7) with (8).
Set torque wrench to 5 Nm.
Tighten the screws (M5x30) according to the following pattern:
- Fuel injector 1:
- Tighten the bolt (1) at an angle of rotation of 90° with the torque wrench.
- Tighten the bolt (2) at an angle of rotation of 90° with the torque wrench.
- Repeat the steps for screws (1) and (2) until 5 Nm is achieved for the two screws.
- Fuel injector 2:
- Tighten the bolt (3) at an angle of rotation of 90° with the torque wrench.
- Tighten the bolt (4) at an angle of rotation of 90° with the torque wrench.
- Repeat the steps for screws (3) and (4) until 5 Nm is achieved for the two screws.
- Fuel injector 3:
- Tighten the bolt (5) at an angle of rotation of 90° with the torque wrench.
- Tighten the bolt (6) at an angle of rotation of 90° with the torque wrench.
- Repeat the steps for screws (5) and (6) until 5 Nm is reached for both screws.
- Fuel injector 4:
- Tighten the bolt (7) at an angle of rotation of 90° with the torque wrench.
- Tighten the bolt (8) at an angle of rotation of 90° with the torque wrench.
- Repeat the steps for screws (7) and (8) until 5 Nm is reached for both screws.
Mark all bolts (1) to (8) with a vertical line (see figure).
Tighten the bolts with the following angles of rotation:
- Tighten the bolt (1) with an angle of rotation of 90°.
- Tighten the bolt (2) with an angle of rotation of 90°.
- Tighten the bolt (3) with an angle of rotation of 90°.
- Tighten the bolt (4) with an angle of rotation of 90°.
- Tighten the bolt (5) with an angle of rotation of 90°.
- Tighten the bolt (6) with an angle of rotation of 90°.
- Tighten the bolt (7) with an angle of rotation of 90°.
- Tighten the bolt (8) with an angle of rotation of 90°.
Fig 2: Fuel Injector Rail Bolts Tightening Sequence
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Check if all bolts (1) to (8) were tightened with an angle of rotation of 90°.
All marks (lines) must be horizontal (see figure).

Fig 3: Fuel Injector Rail Bolts Tightening Sequence
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Release bolts (M6x70) (A) to (D).

The screws must be released .

NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe screwing sequences and tightening torques.
Failure to comply with the regulations can lead to leaks and damage.

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Tighten screw (A) at 5 Nm.
Tighten screw (D) at 5 Nm.
Tighten screw (B) at 5 Nm.
Tighten screw (C) at 5 Nm.
Mark all bolts (A) to (D) with a vertical line (see figure).
Tighten bolts (M6x70) (A) to (D) with an angle of rotation of 90°.

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Check if all bolts (A) to (D) were tightened with an angle of rotation of 90° .
All marks (lines) must be horizontal (see figure).

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Guide the fuel delivery line (3) in and install.
Make sure that the rubber damper (4) is positioned correctly.
Tighten the union nut (1) hand-tight.
Tighten down screws (2).

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TIGHTENING TORQUE SPECIFICATIONS

Fuel delivery line to cylinder head cover
M6x18	tightening torque	7 Nm

Tighten union nut (1).

TIGHTENING TORQUE SPECIFICATIONS

Fuel delivery line to high pressure pump
M14	Tightening torque	26 Nm

Connect and lock the connector (1).
Make sure the connector (1) engages audibly.

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Feed in and position the wiring harness section (2) for the injectors and the ignition coils.
Connect and lock all connectors (1) of the injectors.
Ensure that the connectors (1) of the injectors engage audibly.

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Feed in and install the wiring harness section (4) for the injectors and the ignition coils.
Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Wiring harness section for injectors and ignition coils to cylinder head cover
M6	Tightening torque	6 Nm

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Thread in ground cable (3) and install.
Tighten nut (2).

TIGHTENING TORQUE SPECIFICATIONS

Ground cable to rail
M6	tightening torque	5 Nm

Thread in cable channel (3) and install.
The locks (arrows) must engage audibly.
Connect and lock the connector (1).
Connect and lock the connector (2).
Make sure that the connector (1) and (2) engages audibly.

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Follow-up work

Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE RAIL AND THE HIGH-PRESSURE PUMP .
Refer to INSTALLING THE IGNITION COILS .
Refer to IF INSTALLED: PARTIALLY INSTALLING ENGINE VENTILATION LINE .
Refer to INSTALLING THE UPPER FIREWALL COVER PANEL .
Refer to INSTALLING THE STRUT BRACE .
Refer to INSTALLING FRONT WINDSHIELD PANEL COVER .
Refer to INSTALLING THE REAR HOOD SEAL .
Refer to INSTALLING ACOUSTIC COVER .
Refer to CONNECTING THE BATTERY EARTH LEAD .
Refer to RESET ULTRA-SMALL QUANTITY ADAPTATION .