Installing the high-pressure rail with injectors of the cylinders 1 to 3

• 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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• Observe the position of the cast lug:

  The holder is mounted correctly  when the cast lug lies in the rear.

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• Observe 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 special tool 2 358 022 (1).

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• Replace (M5x30) screws.

  Parts:  Screws (M5x30)

• Mount the injectors with the holders and the bolts (M5x30) (1) on the rail.
• Place the high-pressure rail on a clean folding table in such a way that the openings on the high-pressure rail for the injectors point upwards.

  The electrical injector connections must point in the direction of the fuel pressure sensor.

• Slide special tool 2 358 022 (2) between the holders and the rail onto the injector head.
• Make sure that the special tool 2 358 022 (2) rests flat on the retaining bridge.

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• Hand-tighten both screws (M5x30) (1) evenly until the special tool 2 358 022 (2) rests flat against the rail and the holder.
• Remove special tool 2 358 022 (1).
• Repeat operation on all injectors.

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

  The injectors must be able to move freely.

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• Change screws (A) to (D).

  Parts:  Screws

• Attach the rail (1) with the injectors to the cylinder head from the top.
• Ensure that the injector tips meet the bores in the cylinder head for the injectors.
• 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.

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

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

  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 the reversible ratchet or the torque wrench.

• Tighten screws (M5x30) in pairs (1) with (2), (3) with (4), (5) with (6) in alternating order with 90° until hand-tight. 
• 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 Injector Screws Tightening Sequence

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• Tighten the screws (M5x30) according to the following pattern: 
  • Fuel injector 1: 
  • Tighten screw (1) at an angle of rotation of 90° ±15° with the torque wrench.
  • Tighten screw (2) at an angle of rotation of 90° ±15° 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 screw (3) at an angle of rotation of 90° ±15° with the torque wrench.
  • Tighten screw (4) at an angle of rotation of 90° ±15° 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 screw (5) at an angle of rotation of 90° ±15° with the torque wrench.
  • Tighten screw (6) at an angle of rotation of 90° ±15° with the torque wrench.
  • Repeat the steps for screws (5) and (6) until 5 Nm is achieved for the two screws.
• Mark all bolts (1) to (6) with a line (see figure).
• Tighten screws using an angle of rotation. 
  • Tighten the screw (1) with an angle of rotation of 90° ±15°.
  • Tighten the screw (2) with an angle of rotation of 90° ±15°.
  • Tighten the screw (3) with an angle of rotation of 90° ±15°.
  • Tighten the screw (4) with an angle of rotation of 90° ±15°.
  • Tighten the screw (5) with an angle of rotation of 90° ±15°.
  • Tighten the screw (6) with an angle of rotation of 90° ±15°.
  Fig 2: Fuel Injector Bolts Tightening Sequence (With Line)

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• Check if all bolts (1) to (6) have been tightened with a 90° ±15° angle of rotation.

  All markings (lines) must be horizontal (see Figure).

  Fig 3: Fuel Injector Screws Tightening Sequence

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• Screws (M6x70) (A) to (D) must  be loosened.
  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.

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• Mark all the bolts (A) to (D) with a vertical line (see Figure).
• Tighten the (M6x70) screws from (A) to (D) with an angle of rotation of 90°.

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• Check if all the screws from (A) to (D) were tightened with an angle of rotation of 90°.

  All marks (lines) must be horizontal (see figure).

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• Connect all connectors (3) to the injectors and lock them.

  All the connectors (3) must engage audibly.

• Feed in cable channel (2) and install.
• Tighten nuts (1).

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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 ACOUSTIC COVER AT REAR .
• Refer to INSTALLING THE COWL UPPER PART .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to INSTALLING WINDSHIELD PANEL COVER .
• Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
• Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
• Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
• Refer to ACTIVATING ELECTRICAL SYSTEM .
• Refer to ACTIVATING THE 48 V ELECTRICAL SYSTEM .
• Refer to RESET ULTRA-SMALL QUANTITY ADAPTATION .