Installing the rail with injectors

• Mount the holder (1)  above 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.
• Use the special tool (distance gauge) 2 358 022 (1)  .

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• Mount the injectors with holders and the new  screws (M5x30) to the rail.

  Parts:  Screws (M5x30)

• Place the rail on a clean table that the openings on the rail for the injectors 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.
• Make sure that the special tool (distance gauge) 2 358 022 (2)  rests flat on the retaining bridge.
• Hand-tighten both screws (M5x30) (1)  uniformly until special tool (distance gauge) 2 358 022 (2)  rests flat against the rail and the holder.

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• Remove the special tool (distance gauge)2 358 022 (1)  .
• Repeat this operation for all injectors.

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• Check injectors (1)  for loose fit at the rail.
• Align the electrical injector connections parallel to the rail.

  Injectors (1)  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.
• Replace screws (M6x70) (A)  , (B)  , (C)  , and (D)  .

  Parts:  Screws (M6x70)

• Press down until a resistance can be felt, position screws (M6x70) (A)  , (B)  , (C)  and (D)  , and turn them until hand-tight.

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• Set torque wrench to 2 Nm.
• Tighten the screws (A), (D)  , (B)  and (C)  in alternating order by 90°  each with the torque wrench until the rail is positioned flush on the cylinder head.

  The illustration shows the rail lying flat on the cylinder head.

• If tightening torque (2 Nm) is achieved before the rail rests on the cylinder head: Disassemble the rail and restart the installation procedure.

• Tighten screw (A)  by 5 Nm.
• Tighten screw (D)  by 5 Nm.
• Tighten screw (B)  by 5 Nm.
• Tighten screw (C)  by 5 Nm.
• Connect connectors (2)  and lock.

  The connector (2)  must engage audibly.

• Make sure that the rail (1)  rests flat against the cylinder head.

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• Insert a wrench socket set into an extension.

  Do not use a reversible ratchet or torque wrench.

• Hand-tighten  the screws (M5x30) respectively in pairs (1)  with (2)  , (3)  with (4)  , (5)  with (6)  , (7)  with (8)  alternatively with 90°  .
• Set torque wrench to 5 Nm.
  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 Rail Screws Tightening Sequence

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• Screw the M5x30 screws according to the following pattern: 
  • Fuel injector 1: 
    • Turn screw (1) at an angle of rotation of 90° with the torque wrench
    • Turn screw (2) at an angle of rotation of 90° with the torque wrench
    • Repeat the steps for screws (1) and (2) until 5 Nm is reached for the two screws
  • Fuel injector 2: 
    • Turn screw (3) at an angle of rotation of 90°with the torque wrench
    • Turn screw (4) at an angle of rotation of 90° with the torque wrench
    • Repeat the steps for screws (3) and (4) until 5 Nm is reached for the two screws
  • Fuel injector 3: 
    • Turn screw (5) at an angle of rotation of 90° with the torque wrench
    • Turn screw (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: 
    • Turn screw (7) at an angle of rotation of 90° with the torque wrench
    • Turn screw (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 illustration).
• Tighten screws using an angle of rotation. 
  • Tighten screw (1) at an angle of rotation of 90°
  • Tighten screw (2) at an angle of rotation of 90°
  • Tighten screw (3) at an angle of rotation of 90°
  • Tighten screw (4) at an angle of rotation of 90°
  • Tighten screw (5) at an angle of rotation of 90°
  • Tighten screw (6) at an angle of rotation of 90°
  • Tighten screw (7) at an angle of rotation of 90°
  • Tighten screw (8) at an angle of rotation of 90°
    Fig 2: Fuel Rail Screws Tightening Sequence

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• Check if all the screws from (1)  to (8)  are tightened at an angle of rotation of 90°.

  Marks (lines) must be horizontal (see illustration).

  Fig 3: Fuel Rail Screws 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.
• Tighten screw (A)  at 5 Nm.
• Tighten screw (D)  at 5 Nm.
• Tighten screw (B)  at 5 Nm.
• Tighten screw (C)  at 5 Nm.

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• Mark screws (A)  to (D)  with a vertical line (see illustration).
• Tighten (M6x70) screws (A)  to (D)  at an angle of rotation of  90°.

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• Check if screws (A)  to (D)  were tightened at an angle of rotation of 90°.

  All the marks (lines) must be horizontal (see illustration).

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• Connect and lock all the connectors (1)  to the injectors.

  All connectors (1)  must engage audibly.

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• Thread the cable channel (3)  in and install.
• Thread in ground cable (2)  and install.
• Tighten nut (1)  .
  TIGHTENING TORQUES SPECIFICATION
  
  

  Ground cable to rail
  M6	tightening torque	5 Nm

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Follow-up work 

• Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
• Refer to INSTALLING ALL IGNITION COILS .
• Refer to INSTALLING THE CYLINDER HEAD COVER ACOUSTIC COVER .
• Refer to INSTALLING ACOUSTIC COVER AT REAR .
• Refer to INSTALLING THE REAR HOOD SEAL .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to ACTIVATING VEHICLE ELECTRICAL SYSTEM .
• Refer to RESET ULTRA-SMALL QUANTITY ADAPTATION .