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Injectors

Injectors

To remove

Warning

Removing the fuel rails involves work on the car's fuel system. The following points must therefore be considered in connection with the work:



• Make provision for good ventilation! If approved ventilation for extracting fuel fumes is available then it must be used.

• Use protective gloves! Prolonged contact with fuel may irritate the skin.

• Keep a class BE fire extinguisher close at hand! Watch out for sparks, e.g. in connection with breaking electric circuits, short-circuits, etc.

• Smoking is absolutely forbidden.



1. Remove the camshaft, see 2. Basic Engine, Adjustment/replacement, Camshaft .


2. Suck up the oil on top of the cylinder head.

3. Detach the air hose from the intake manifold, bend it to one side and plug it.

4. Unplug all the cables connected to the wiring harness channel and cut the securing points. Remove the channel from the cylinder head and lay it over the engine.

5. Pull off the vacuum hose from the EGR valve.

6. Note the position of the fuel rails and their clips and mark them.


7. Remove the fuel return hoses from the cylinder head.

8. Remove the fuel rails (remove the clips if necessary).

9. Slightly loosen the fuel line connections on the fuel pump.

10. Remove the upper part of the intake manifold and seal the passageways.


11. Remove the fuel bridge retaining screws and pull the fuel bridges out of the cylinder head.

12. Remove the seals on the injector connections in the cylinder head.

13. Screw adapter 83 95 378 onto the fuel injectors, fit extractor 87 91 360 to the adapter and pull out the fuel injectors.


14. Remove the seals from the fuel injectors.


To fit



1. Fit new seals onto the fuel injectors and fit the injectors.

2. Fit new seals on the injector connections in the cylinder head. Remove any old sealing compound remains.

3. Blow out the holes for the fuel bridge retaining bolts. Fit new O-rings on the fuel bridges, lubricate the O-rings with non-acidic vaseline and carefully slide the fuel bridges into the cylinder head.


4. Tighten the fuel bridge bolts.

Tightening torque 5 Nm + 360° (4 lbf ft + 360°)

5. Clean the sealing surfaces.

6. Fit a new gasket to the lower part of the intake manifold and fit the upper part.

Tightening torque 10 Nm (7 lbf ft).

7. Fit the pressure sensor and EGR valve if the intake manifold has been changed.

8. Tighten the fuel lines to the fuel pump.


Tightening torque 25 Nm (18.5 lbf ft).

9. Check the fuel rail connecting cones and replace them if necessary.

10. Connect the fuel rails with clips in their original positions.

Tightening torque 25 Nm (18.5 lbf ft).

11. Check the condition of the fuel return hoses and joints and replace as necessary.

12. Connect the fuel return hoses to the fuel bridges. Detach the fuel return hose from the fuel pump and connect the hose to pressure/vacuum pump 30 14 883. Pump up a vacuum of 750 mbar and wait 1 minute. Check that the pointer on the tool has not moved.

If there is found to be a leak, the fuel bridges must be examined individually. Connect the pressure/vacuum pump to the return fuel connection (not to the return hose) on each fuel bridge. If the fuel bridges are OK, check the return fuel hoses with T-pieces. The hoses should be pliable and exhibit no cracks or other damage. If there are signs of leakage, change all fuel return hoses with T-pieces. If there is leakage in the fuel bridge, remove it, change the seal and refit the bridge. Check for leakage once again.

13. Connect the vacuum hose to the EGR valve.


14. Fit the wiring harness channel to the engine.

15. Secure the wiring harness as it was previously.

16. Refit the hose to the intake manifold.

17. Fit the camshaft. See Camshaft .