Installing the rail

• Mount the holder (1) via 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).

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• Replace the bolts (1) (M5x30).

  Parts:  Screws (M5x30)

• Mount the injectors with the holders and the new screws (1) (M5x30) on the rail.
• Place the rail on a clean table so that the openings for the injectors on the rail 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. 
• Tighten both the new bolts (1) (M5x30) evenly by hand, until the special tool (distance gauge) 2 358 022 (2) rests flat on rail and on holder. 

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• 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 position of the electrical injector connections parallel to the rail.

  The injectors 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.
• Push the rail (1) down until a resistance can be felt.

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• Replace the screws (A), (B), (C) and (D) (M6x70).

  Parts:  Screws (M6x70)

• Position the new screws (A), (B), (C) and (D) (M6x70) and hand-tighten them.
• Set torque wrench to 2 Nm.
• Apply the screws (A), (D), (B) and (C) in alternating order in 90° steps.
• If the tightening torque of (  2 Nm )  is reached before the rail (1) is on the cylinder head (2) lie: Disassemble the rail (1) and repeat the installation procedure.

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• Tighten bolt (A) with 5 Nm.
• Tighten bolt (D) with 5 Nm.
• Tighten bolt (B) with 5 Nm.
• Tighten bolt (C) with 5 Nm.

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• Attach a socket to an extension.

  Do not  use a reversible ratchet or torque wrench.

• Tighten the bolts (M5x30) in pairs in 90° increments  hand-tight. Observe the following sequence: (1) with (2), (3) with (4), (5) with (6) and (7) with (8).
• Set torque wrench to 5 Nm.
• Tighten the screws (M5x30) 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 the bolts with the following angles 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 bolts (1) to (8) were tightened with an angle of rotation of 90°.

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

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• Release bolts (M6x70) (A) to (D).

The screws must be released

• Tighten bolt (A) to 5 Nm:
• Tighten bolt (D) to 5 Nm:
• Tighten bolt (B) to 5 Nm:
• Tighten bolt (C) to 5 Nm:

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• Mark all 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 bolts (A) to (D) were tightened with an angle of rotation of 90°  .

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

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• Guide the fuel delivery line (3) in and install.
• Make sure that the rubber damper (4) is positioned correctly.
• Tighten the union nut (1) hand-tight.
• Tighten down screws (2).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Fuel delivery line to cylinder head cover
  M6x18	tightening torque	7Nm

• Tighten union nut (1).

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  TIGHTENING TORQUES SPECIFICATION
  
  

  Fuel delivery line to high pressure pump
  M14	Tightening torque	26Nm

• Connect and lock the connector (1).
• Make sure the connector (1) engages audibly.

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• Feed in and position the wiring harness section (2) for the injectors and the ignition coils.
• Connect and lock all connectors (1) of the injectors.
• Ensure that the connectors (1) of the injectors engage audibly.

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• Feed in and install the wiring harness section (4) for the injectors and the ignition coils.
• Tighten down screw (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Wiring harness section for injectors and ignition coils to cylinder head cover
  M6	Tightening torque	6Nm

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

  Ground cable on rail
  M6	Tightening torque	5Nm

• Thread in cable channel (3) and install.
• The locks (arrows) must engage audibly.
• Connect and lock the connector (1).
• Connect and lock the connector (2).
• Make sure that the connector (1) and (2) engages audibly.

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Follow-up work 

• Refer to INSTALL THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE RAIL AND THE HIGH-PRESSURE PUMP .
• Refer to INSTALLING THE IGNITION COILS .
• Refer to IF INSTALLED: PARTIALLY INSTALL ENGINE VENTILATION LINE .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to INSTALLING THE UPPER BULKHEAD COVER PANEL .
• Refer to INSTALLING THE STRUT BRACE .
• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to INSTALLING FRONT WINDSHIELD PANEL COVER .
• Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .