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Fuel rail, 4-cyl.

Fuel rail, 4-cyl.

To remove

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 near at hand! Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.

• No smoking anywhere in the vicinity.


Important

Great cleanliness must be observed when working on the fuel rail and injectors. Clean the injectors, fuel-injection rail and intake manifold. Blow clean with compressed air.



1. Remove the upper engine cover.


2. Remove the charge air pipe from the turbocharger and camshaft cover, move it aside and plug the hose and turbocharger inlet.

3. Remove the charge air hose from the throttle body, plug it and move it aside.

4. Unplug the temperature/pressure sensor connector and the ground cable. Remove the throttle body. Plug the intake manifold.


5. Unplug the connector. Detach and move aside the EGR valve.

6. Detach the engine harness from the oil filter housing.

7. Detach the fuel return hoses from the fuel bridges.

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


9. Remove the fuel rails with clips. Remove following the order of the cylinders.


To fit


1. Check the fuel rail connecting cones. Replace the rails as necessary. Fit the fuel lines with clips to the fuel bridges and fuel pump.


Tightening torque: 25 Nm (18 lbf ft).

2. Fit new fuel return hoses. Check the condition of the T-pieces. Replace as necessary.

Tightening torque: 25 Nm (18 lbf ft).

3. Fit the lower clip for the wiring harness to the oil filter housing.


4. Fit the EGR valve with new O-ring and plug in its connector.

Tightening torque: 8 Nm (6 lbf ft)

5. Fit the throttle body with new seal; plug in the temperature/pressure sensor connector and the ground cable.

Tightening torque: 10 Nm (7 lbf ft)

6. Fit the turbo pressure hose to the throttle body.


7. Connect the turbocharger delivery pipe to the turbocharger and fit the charge air pipe to the camshaft cover.

8. Bleed the fuel system. See Bleeding fuel line, 4-cyl .

9. Replace the upper engine cover.