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Fuel rail with injectors (B235R, B205L/R)

Fuel rail with injectors (B235R, B205L/R)

Warning

Removal of the fuel rail involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work:

• Work only in a well-ventilated area! If approved equipment for the extraction of fuel vapours is available, be sure to use it.

• Wear suitable gloves! Prolonged contact with fuel can cause skin irritation or dermatitis.

• Keep a class BE fire extinguisher close at hand! Beware of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.

• No smoking anywhere in the vicinity.


Dismantling

Important

The utmost cleanliness must be observed when handling the fuel rails and injectors. Wash around the injectors, fuel rail and intake manifold and dry with compressed air.



1. Remove the upper engine cover.


2. Remove fuse 32 for the fuel pump while the engine is running. Switch off the ignition once the engine has stopped. Refit fuse 32 for the fuel pump.

3. Detach the crankcase ventilation hoses.


4. Disconnect the fuel line connections from the fuel rail using special tool 83 95 261 Fuel line tool .

Use also a rag or other cloth to collect excess fuel.

5. Remove the dipstick and filler pipe and plug the pipe.

6. Remove the cover over the throttle valve. Detach the accelerator wire from the throttle spindle. Remove the accelerator wire with holder and bend it to one side.

7. Detach the cable channel, 3 screws, and put it to one side.


8. Cut the cable tie securing the check valve to the camshaft cover.

9. Unplug the injector connectors.

Important

Secure each injector clip with a narrow cable tie. Make sure they are positioned correctly and tighten them. Otherwise, the injectors may come loose from the fuel rail while being removed.


10. Blow clean around the injectors with compressed air.

11. Undo the two rail retaining screws.


12. Detach the pressure regulator vacuum hose.

13. Carefully prise off the rail using 2 crowbars or similar tool.

14. Carefully lift out the rail.

15. Plug the nozzle holes.


To fit


1. Remove the plugs in the nozzle holes and lubricate the injector O-rings with acid-free vaseline, part no. 30 06 665.


2. Carefully lift the rail.

3. Fit the rail with fuel rail, 2 screws.

4. Connect the pressure regulator vacuum hose.

5. Remove the cable ties round the injectors.

6. Spray the injector valve connectors with Kontakt 61, part no. 30 04 520, and plug them in.

7. Replace the cable channel and fit the 3 screws.


8. Secure the check valve to the camshaft cover with a cable tie.

9. Fit the throttle cable and bracket. Adjust the throttle cable.


10. Fit the cover over the throttle valve.

11. Fit the dipstick and filler pipe.

12. Connect the crankcase ventilation hoses.

13. Attach the fuel connections to the fuel rail.

14. Fit the upper engine cover.