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Injectors

Injectors



Warning

Removal of the fuel pressure regulator 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 vapour is available then make sure it is used.

• Wear protective gloves! Prolonged contact with fuel can cause skin irritation.

• Keep a class BE fire extinguisher close by! Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.

• Smoking is strictly forbidden.

• Wear protective goggles.


Important

Thorough cleanliness must be observed when working on the fuel line and injectors. Blow clean the injectors, fuel line and intake manifold with compressed air.


To remove


1. Remove fuse 19 while the engine is running.


2. Turn off the ignition once the engine has stopped. Refit the fuse.

3. Remove the cover on the throttle body pedal arm.

4. Detach the hose to the crankcase ventilation.

5. Remove the oil dipstick with filler pipe (2 screws) and plug the pipe.

6. Detach the accelerator pedal wire from the pedal arm on the throttle body and bend it to one side.


7. Slacken the turbocharger delivery pipe retaining screw in the cylinder head.

8. Undo the hose clips and turn the hose elbow upwards.

9. Slacken the wiring holder upper front bolt.


10. Remove the rear bolt.

11. Lift up the wiring holder and bend it backwards.

12. Undo the following connectors: ignition discharge module, injectors, manifold absolute pressure sensor, mass air flow sensor and turbo pressure sensor.


13. Loosen the cable and bend them to one side.

Important

Secure each injector clip with a narrow cable tie. Make sure that it is correctly fitted and then tighten it. If this is not done, the injectors could come loose from the fuel rail during the flow test.


14. Clean the area round the injectors with compressed air.

15. Remove the fuel rail retaining bolts.

16. Disconnect the pressure regulator vacuum hose.

17. Carefully prise loose the rail using 2 crowbars or similar tool.

18. Carefully lift the rail up and away.

19. Plug the nozzle orifices.


To fit


Note

Lubricate the O-rings with acid-free vaseline to facilitate assembly.



1. If necessary, fit new O-rings on the injectors. Remove the plugs from the orifices and fit the fuel rail with its injectors in position.

Tightening torque: 8 Nm (5.9 lbf ft)

2. Fit the pressure regulator vacuum hose.

3. Screw in the two rail retaining screws.

4. Fit the wiring to the fuel rail.

5. Fit the following connectors: ignition discharge module, injectors, manifold absolute pressure sensor, mass air flow sensor and turbo pressure sensor.

Important

Make sure the connectors are fitted to the correct injector, the cables are marked. Spray all the connectors with Kontakt 61 (part no. 30 04 520) before plugging them in.


6. Fit the wiring holder.


7. Screw in the rear screw.

8. Tighten the front screw.

9. Connect the hose and fit the hose clips.


10. Tighten the turbocharger delivery pipe retaining screw on the cylinder head.

11. Attach the accelerator pedal wire to the pedal arm on the throttle body and tighten the three screws. Adjust the wire if necessary.

12. Remove the plug and fit the dipstick with filler pipe and the cover on the throttle body pedal arm.


13. Connect the hose for crankcase ventilation.

14. Start the engine and carry out an inspection for leakage.

15. Fit the engine cover.