Installing the high-pressure rail with injectors of the cylinders 4 to 6

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

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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) evenly until the special tool (distance gauge) 2 358 022  (2) rests flat on 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 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 hit the holes provided in the cylinder head for this.
• Ensure that the guides on the injector are slid correctly into the guide bore holes in the cylinder head.

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• Press high-pressure rail (1) downwards until a resistance is felt; position the screws (M6x30) (A) and (B) and hand-tighten them.
• Set torque wrench to 2 Nm.
• Tighten the screws (A) and (B) alternately by 180°  each with the torque wrench, till the rail is positioned on the cylinder head.

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

• Insert screws (C) and (D).

• Tighten screw (A) by 5 Nm.
• Tighten screw (D) by 5 Nm.
• Tighten screw (B) by 5 Nm.
• Tighten screw (C) by 5 Nm.
• 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.

• Tighten the bolts (M5x30) in pairs ((1) with (2), (3) with (4), (5) with (6)) in alternating order 90° handtight  .
• Set torque wrench to 5 Nm.

Fig 1: Rail, Injector Bolts Tightening Sequence

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• Tighten the screws (M5x30) according to the following pattern: 
  • Fuel injector 4: 
  • 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 5: 
  • 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 6: 
  • 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 vertical 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, Injector Bolts 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, Injector Bolts Tightening Sequence

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  • Release bolts (M6x70) (A) to (D).

The screws must be released  .

• Tighten screw (A) by 5 Nm.
• Tighten screw (D) by 5 Nm.

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• 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 markings (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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