Fuel rail with injectors, 4 cyl.
|
Fuel rail with injectors, 4 cyl.
|
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
|
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 engine cover by undoing on snap fastener at a time, starting at the oil filler cap.
|
2.
|
Remove fuse 19 with the engine running. Turn the ignition key to OFF when the engine has stopped. Put back the fuse.
|
3.
|
Detach the crankcase ventilation hose.
|
4.
|
Take out the dipstick with oil filler pipe end and plug the pipe.
|
5.
|
Remove the cover over the throttle disc. Detach the throttle cable from the throttle spindle. Remove the throttle cable with holder and put it to one side.
|
6.
|
Undo the turbocharger delivery pipe retaining screw in the cylinder head.
|
7.
|
Undo the hose clips and turn the hose elbow upwards.
|
8.
|
Slacken the upper front bolt of the wiring holder.
|
10.
|
Lift up the wiring holder and bend it rearwards.
|
11.
|
Unplug the following connectors: ignition discharge module, injectors, manifold absolute pressure sensor, boost pressure control valve and turbo pressure sensor.
|
12.
|
Disconnect the wiring and bend it aside. The rail has 2 cable ties and there are 3 clips on the crankcase ventilation pipe.
Important
|
Lubricate the injector O-rings with acid-free petroleum jelly before fitting. Make sure that the injectors are properly pressed in, ensuring they bottom in the fuel rail.
|
The injectors must be fitted with the connector pointing upwards.
|
|
|
13.
|
Clean the area round the injectors with compressed air.
|
14.
|
Remove the 2 fuel rail retaining bolts.
|
15.
|
Disconnect the pressure regulator vacuum hose.
|
16.
|
Carefully prise loose the rail using 2 pry bars or similar tools.
|
17.
|
Carefully lift up the fuel rail and place it to one side.
|
18.
|
Plug the nozzle orifices.
|
Important
|
Make sure the correct connector is plugged onto the correct valve as indicated by the markings on the cables.
|
|
1.
|
Fit the new injectors. Press the injector clips into place.
Important
|
Lubricate the injector O-rings with acid-free petroleum jelly before fitting and check that the injectors are pressed all the way home in the fuel rail. Make sure they are fitted with the connectors straight up.
|
|
|
2.
|
Remove the plugs from the nozzle orifices in the cylinder head.
|
3.
|
Carefully fit the fuel rail.
|
4.
|
Tighten the 2 fuel rail retaining bolts.
|
5.
|
Connect the pressure regulator vacuum hose.
|
6.
|
Connect the fuel lines.
|
7.
|
Lay out and secure the wiring with 2 cable ties on the fuel rail and 3 clips on the crankcase ventilation pipe.
|
8.
|
Connect the injectors, manifold absolute pressure sensor, boost pressure control valve and turbo pressure sensor.
Important
|
Spray the connectors with Kontakt 61, part no. 30 04 520, before connecting them.
|
Make sure that each connector is connected to the right injector. The cables are marked.
|
|
|
9.
|
Position the wiring holder and tighten the retaining screws.
|
10.
|
Fit the turbocharger delivery pipe and tighten the screws on the hose clamps.
|
11.
|
Position the throttle cable with holder, and fit the throttle cable.
|
12.
|
Fit the cover over the throttle disc.
|
13.
|
Remove the plug and fit the dipstick with filler pipe.
|
14.
|
Connect the hose for crankcase ventilation.
|
15.
|
Fit the upper engine cover.
|