Install injectors

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.
Version with cast lug on holder (1):
Ensure that the installation position of the holder is correct.

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If necessary, check 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, check 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.

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Use special tool 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 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 2 358 022 (2) between the holders and the rail on to the injector head.

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Make sure that the special tool 2 358 022 (2) lies on the retaining bridge.
Tighten both the screws (M5x30) (1) evenly by hand 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 (1) for loose fit at the rail.
Align the position of the electrical injector connections parallel to the rail.
Injectors (1) 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.
Press down until a resistance can be felt; apply the (M6x70) screws (A), (D), (B) and (C) and hand-tighten them.
Set 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 illustration shows the rail lying flat on the cylinder head.
If tightening torque (2 Nm) is achieved before the rail rests on the cylinder head: Disassemble the rail and restart the installation procedure.

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) with 5 Nm.
Tighten bolt (D) with 5 Nm.
Tighten bolt (B) with 5 Nm.
Tighten bolt (C) with 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.
Manually tighten the screws (M5x30) in pairs ((1) with (2), (3) with (4), (5) with (6), (7) with (8)) alternately by 90° .
Set torque wrench to 5 Nm.

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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.

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 illustration).
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) have been tightened up to (8) with an angle of rotation of 90°.
All markings (lines) must be horizontal (see Illustration).

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Release bolts (M6x70) (A) to (D).
The screws must be released.

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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Tighten bolt (A) to 5 Nm:
Tighten bolt (D) to 5 Nm:
Tighten bolt (B) to 5 Nm:
Tighten bolt (C) to 5 Nm:
Mark all the bolts (A) to (D) with a vertical line (see Illustration).
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 markings (lines) must be horizontal (see Illustration).

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Connect and lock all the connectors (1) to the injectors.
All connectors (1) must engage audibly.

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Thread the cable channel (3) in and install.
Thread in ground cable (2) and install.
Tighten nut (1).

TIGHTENING TORQUE SPECIFICATIONS

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 protection (1) on the cylinder head cover.

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

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