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.

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• Use the special tool (distance gauge) 2 358 022 (1).
• 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.
• 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.
• Press down until a resistance can be felt, position screws (M6x70) (A), (B), (C) and (D), and turn them until hand-tight.
• 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.

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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 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: 
    • 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 screws using an angle 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°.
• Check if all bolts (1) to (8) were tightened with an angle of rotation of 90°.

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

  Fig 2: Fuel Rail Bolts Tightening Sequence

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  Fig 3: Fuel 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 screws (A) to (D) with a vertical line (see figure).
• Tighten the screws (M6x70) (A) to (D) at an angle of rotation of 90° 

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• Check if screws (A) to (D) were tightened with 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 TORQUE 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 FRONT HOOD SEAL AT THE REAR .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to CONNECTING NEGATIVE BATTERY CABLE OF THE SYSTEM BATTERY .
• Refer to RESET ULTRA-SMALL QUANTITY ADAPTATION .