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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 .


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

3. Detach the air hose from the throttle body. Bend it to one side and plug it.

4. Bend aside the wiring harness duct.

5. Unplug the EGR valve.

6. Remove the throttle body.

7. Remove the bolts securing the EGR valve and move the valve to one side.

8. Remove the fuel return hoses.


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

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

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


12. Remove the retaining screws for the fuel bridges, lift the fuel bridges and pull them out of the cylinder head.

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

14. Screw Removal tool, injectors 83 95 378 to the injectors, fit Puller 87 91 360 to the adapter and pull out the injectors.


15. 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 the holes for the fuel bridge retaining bolts clean.

4. Fit new O-rings on the fuel bridges, lubricate the O-rings with acid-free petroleum jelly and slide the fuel bridges into the cylinder head.


5. Tighten the fuel bridge bolts.

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

6. Clean the sealing surfaces.

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

Tightening torque 10 Nm (7 lbf ft).

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

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

Tightening torque 25 Nm (19 lbf ft)


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

11. Connect the fuel return hoses to the fuel bridges. Detach the fuel return hose from the fuel pump and connect the hose to 30 14 883 Pressure/vacuum pump . Create 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.


12. Fit the EGR valve and throttle body. Plug in the EGR valve.


13. Fit the wiring harness channel to the engine.

14. Secure the wiring harness as it was previously.

15. Refit the hose to the intake manifold.

16. Fit the camshaft, refer to Camshaft .