Installing the rail

• Mount the holder (1) above the bayonet closure on (2) the injector.
• If the bracket (1) has a cast lug:  Make sure that the holder is installed in the correct position.

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• If applicable, note the position of the cast lug: 

  The holder is mounted correctly  when the cast lug is located at the rear.

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• If applicable, note the position of the cast lug: 

  The holder is mounted incorrectly  when the cast lug (1) is in 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 gouge) 2 358 022  (1).
• Mount the injectors with holders and the new  bolts (M5x30) to the rail.

  Parts:  Screws (M5x30)

• Place the high-pressure rail on a clean table so that the openings on the high-pressure rail for the injectors point up.

  The electrical injector connections must point to the fuel pressure sensor.

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

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

  The injectors (1) must shift freely.

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• Attach the rail (1) with the injectors to the cylinder head from the top.
• Make sure the injector tips catch the corresponding holes for the injectors in the cylinder head.
• Make sure the guides on the injector are properly inserted into the guide bore holes in the cylinder head.
• Press down until resistance can be felt; position and hand-tighten the screws (M6x70) (A), (D), (B) and (C).
• Set the torque wrench to 2 Nm.

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• 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 figure shows the rail resting flat against the cylinder head.

• If the tightening torque (2 Nm) is reached before the rail rests on the cylinder head: Disassemble rail and start the installation procedure again.
  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) to 5 Nm.
• Tighten bolt (D) to 5 Nm.
• Tighten bolt (B) to 5 Nm.
• Tighten bolt (C) to 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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• Attach a wrench socket set to an extension.

  Do not use a reversible ratchet or torque wrench.

• Tighten the screws (M5x30) in pairs ((1) with (2), (3) with (4), (5) with (6), (7) with (8)) in alternating order to 90° hand-tight  .
• Set the 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: Injector Fuel Rail Screws/Bolts (High Pressure) Tightening Sequence

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• Screw the M5x30 screws according to the following plan: 
  • 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 operations for bolts (1) and (2) until both bolts reach a torque of 5 Nm.
  • 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 operations for bolts (3) and (4) until both bolts reach a torque of 5 Nm.
  • 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 operations for bolts (5) and (6) until both bolts have reached a torque of 5 Nm.
  • 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 operations for bolts (7) and (8) until both bolts reach a torque of 5 Nm.
• 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°.

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• Check if all screws (1) to (8) have been tightened with a 90° angle of rotation.

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

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• Release screws (M6x70) (A) to (D).

  It is imperative that the bolts are unscrewed. 

  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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• Apply screw (A) with 5 Nm.
• Apply screw (D) with 5 Nm.
• Apply screw (B) with 5 Nm.
• Apply screw (C) with 5 Nm.
• Mark bolts (A) to (D) with a vertical line (see figure).
• Tighten screws (M6x70) (A) to (D) with 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°  .

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

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

  All connectors (1) must audibly engage.

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

  Ground cable to rail
  M6	Tightening torque	5 Nm

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• Unscrew the sealing cap (1) from the oil filler neck.

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• Mount the drip shield (1) on the cylinder head cover.

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• Screw the sealing cap (1) onto the oil filler neck.

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Follow-up work 

• Install the HIGH-PRESSURE LINE  between the high-pressure pump and the high-pressure rail.
• Install the cylinder head cover ACOUSTIC COVER .
• Install the IGNITION COILS .
• Install rear ACOUSTIC COVER .
• Install the upper part COWL .
• Install windshield panel COVER .
• Install the rear right engine compartment COVER .
• Install the rear left engine compartment COVER .
• Install left and right WIPER ARM .
• Install ACOUSTIC COVER .
• Install the front hood rear SEAL .
• Reconnect all battery GROUND LEADS