Installing rail with injectors of cylinders 1 to 3

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

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Observe the position of the cast lug:
The holder is correctly mounted if the cast lug is at the rear.

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Observe the position of the cast lug:
The holder is incorrectly mounted if the cast lug (1) is at 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 rail on a clean table so that the openings on the rail for the injectors point upwards.
The electrical injector connections must point towards the fuel pressure sensor.
Slide special tool 2 358 022 (2) between the holders and the rail onto the injector head.

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Make sure that the special tool 2 358 022 (2) rests flat on the retaining bridge.
Hand-tighten both screws (M5x30) (1) evenly until the special tool 2 358 022 (2) rests flat against the rail and the holder.
Remove the special tool 2 358 022 (1).
Repeat this operation for 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 freely movable.

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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.
Make sure that the injector tips fit into the bores provided for the injectors in the cylinder head.
Make sure that the guides on the injector are correctly inserted into the guide bore holes in the cylinder head.
Press down until a resistance can be felt; fit the screws (M6x70) (A), (B), (C) and (D) and hand-tighten them.
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.

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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 and lock the connector (2).
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 screws (M5x30) in pairs ((1) with (2), (3) with (4), (5) with (6)) alternately by 90° .
Set torque wrench to 5 Nm.

Fig 1: Rail Screws Tightening Sequence
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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.
Screw the (M5x30) screws according to the following scheme:
- 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 reached for both 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 reached for both 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 reached for both 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°.
  
  Fig 2: Rail Screws Tightening Sequence
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- Tighten the screw (5) with an angle of rotation of 90° ±15°.
- Tighten the screw (6) with an angle of rotation of 90° ±15°.
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: Rail 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.
Mark all the 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 screws (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 connector (3) to the injectors and lock. All the connectors (3) must engage audibly.
Feed in cable channel (2) and install.

Tighten nuts (1).

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TIGHTENING TORQUE SPECIFICATIONS

Ground cable to rail
M6	tightening torque	5 Nm