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 the correct installation position of the holder.

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

  The holder is correctly  mounted if the cast lug is at the rear.

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• If necessary note 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 replaceed. 

  • 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 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 so 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.
• 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.

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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 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 holes provided for that 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.

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

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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 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° hand-tight  .
• Set 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: Rail, Injector Bolts Tightening Sequence

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• Screw the (M5x30) screws according to the following scheme: 
  • 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 reached for both 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 reached for both 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 reached for both 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°.
  • 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 2: Rail, Injector Screws Tightening Sequence

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  Fig 3: Rail, Injector Bolts Tightening Sequence

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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 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 markings (lines) must be horizontal (see Figure).

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

  All connectors (1) must engage audibly.

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• Thread in cable channel (3) and install.
• Thread in ground cable (2) and install.
• Tighten nuts (1).
  TIGHTENING TORQUES SPECIFICATION
  
  

  Ground cable to rail
  M6	Tightening torque	5 Nm

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Follow-up work 

• Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
• Refer to INSTALL ALL IGNITION COILS .
• Refer to INSTALLING ACOUSTIC COVER AT REAR .
• Refer to INSTALL THE FRONT HOOD SEAL AT THE REAR .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to ACTIVATING THE 48 V ELECTRICAL SYSTEM .
• Refer to RESET ULTRA-SMALL QUANTITY ADAPTATION .