Fuel rail with injectors, 4 cyl.
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Fuel rail with injectors, 4 cyl.
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Warning
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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:
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Make sure a class BE fire extinguisher is close to hand! Consider the risk of sparking, e.g. when breaking circuits, short-circuits etc.
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Absolutely No Smoking!
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Ensure that there is a good exchange of air. If approved ventilation for the extraction of fuel fumes is available, this should be used.
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Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.
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Wear protective goggles.
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Important
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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.
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1.
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Remove the engine cover by undoing on snap fastener at a time, starting at the oil filler cap.
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2.
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Remove fuse 19 with the engine running. Turn the ignition key to OFF when the engine has stopped. Put back the fuse.
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3.
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Detach the crankcase ventilation hose.
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4.
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Take out the dipstick with oil filler pipe end and plug the pipe.
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5.
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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.
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6.
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Undo the turbocharger delivery pipe retaining screw in the cylinder head.
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7.
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Undo the hose clips and turn the hose elbow upwards.
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8.
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Slacken the upper front bolt of the wiring holder.
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10.
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Lift up the wiring holder and bend it rearwards.
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11.
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Unplug the following connectors: ignition discharge module, injectors, manifold absolute pressure sensor, boost pressure control valve and turbo pressure sensor.
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12.
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Disconnect the wiring and bend it aside. The rail has 2 cable ties and there are 3 clips on the crankcase ventilation pipe.
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Important
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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.
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The injectors must be fitted with the connector pointing upwards.
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13.
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Clean the area round the injectors with compressed air.
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14.
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Remove the 2 fuel rail retaining bolts.
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15.
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Disconnect the pressure regulator vacuum hose.
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16.
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Carefully prise loose the rail using 2 pry bars or similar tools.
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17.
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Carefully lift up the fuel rail and place it to one side.
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18.
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Plug the nozzle orifices.
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Important
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Make sure the correct connector is plugged onto the correct valve as indicated by the markings on the cables.
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1.
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Fit the new injectors. Press the injector clips into place.
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Important
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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.
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2.
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Remove the plugs from the nozzle orifices in the cylinder head.
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3.
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Carefully fit the fuel rail.
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4.
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Tighten the 2 fuel rail retaining bolts.
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5.
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Connect the pressure regulator vacuum hose.
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6.
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Connect the fuel lines.
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7.
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Lay out and secure the wiring with 2 cable ties on the fuel rail and 3 clips on the crankcase ventilation pipe.
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8.
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Connect the injectors, manifold absolute pressure sensor, boost pressure control valve and turbo pressure sensor.
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Important
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Spray the connectors with Kontakt 61, part no. 30 04 520, before connecting them.
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Make sure that each connector is connected to the right injector. The cables are marked.
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9.
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Position the wiring holder and tighten the retaining screws.
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10.
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Fit the turbocharger delivery pipe and tighten the screws on the hose clamps.
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11.
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Position the throttle cable with holder, and fit the throttle cable.
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12.
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Fit the cover over the throttle disc.
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13.
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Remove the plug and fit the dipstick with filler pipe.
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14.
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Connect the hose for crankcase ventilation.
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15.
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Fit the upper engine cover.
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