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Fuel rail, Z19DT

Fuel rail, Z19DT

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:

• Make sure a class BE fire extinguisher is close to hand! Consider the risk of sparking, e.g. when breaking circuits, short-circuits etc.

• Absolutely No Smoking!

• Ensure that there is a good exchange of air. If approved ventilation for the extraction of fuel fumes is available, this should be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.


Important

Be very thorough in terms of cleanliness when working in the fuel system. Malfunctions can also occur due to very small dirt particles. Prevent dirt from entering the fuel system by cleaning the hoses and plugging the pipes and lines upon removal using 93 161 370 Plug set. Store the components so that contaminants cannot enter.


Important

Always use wing covers when working in the engine bay.


To remove

Warning

Diesel under high pressure! So wait for at least one minute after switching off the engine before starting work in the fuel system. Diesel fumes are explosive and can cause severe burn injuries.


Warning

Exercise caution as the engine can be very hot.



1. Remove the upper engine cover and insulation.

2. Remove the injector connectors.


3. Detach the wiring harness from the intake manifold.

4. Remove the return fuel collector bolts.


5. Remove the fuel return hose from the fuel rail.

6. Remove the delivery line between the fuel rail and the high pressure pump.

Note

Use an open spanner as a counterhold when undoing the cap nut.


7. Remove the delivery lines between the injectors and the fuel rail.

Note

Use an open spanner as a counterhold when undoing the cap nut.



8. Remove the connector on each end of the fuel rail.


9. Remove the fuel rail.


To fit


1. Fit the fuel rail.


2. Plug in the connectors on each end of the fuel rail.

3. Check that the fuel pipe sealing surfaces are clean and not damaged. Fit the pipe without tensioning it and mount the nuts by hand. Fit the pipes between the fuel rail and the injectors.

Tightening torque 25 Nm (18 lbf ft)



4. Fit the pipe between the fuel rail and the high pressure pump.

Tightening torque 25 Nm (18 lbf ft)

5. Fit the fuel return hose to the fuel rail.

6. Fit the return fuel collector bolts.

7. Plug in the connectors to the injectors.


8. Fit the wiring harness to the intake manifold.

9. Connect an exhaust hose and start the engine. Check the integrity of the fuel system.

Connect the diagnostic tool and erase any diagnostic trouble codes.

10. Fit the insulation and the upper engine cover.