Fuel Rail: Service and Repair

AR07.03-P-1451H Remove/Install Fuel Rail With Injectors

Shown On Engine 285:

Remove/Install

DANGER:
- Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.
- Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.
- Risk of death. Death may result if contact is made with parts carrying high voltages.
- Do not touch parts carrying high voltages.
- Persons who wear electronic implants (e.g. heart pacemakers) must not carry out work on the ignition system.
- Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from contact with fuel.
- No fire, sparks, naked flames or smoking.
- Pour fuels only into suitable and appropriately marked containers.
- Wear protective clothing when handling fuel.
- Risk of injury to fingers being jammed or squeezed when removing and installing or aligning hoods, doors, trunk lid/tailgate or sliding roof.
- When moving components, ensure that no body parts or limbs are within the operating range of moving parts.

1 Open engine hood

DANGER:
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
- No fire, sparks, naked flames or smoking.
- Wear protective gloves, acid-resistant clothing and safety glasses. Pour battery electrolyte only into suitable and appropriately marked containers.

2 Disconnect ground cable of battery
3 Remove charge air cooler
4 Remove ECI power pack
5 Remove purge line (1) on the bracket (2) of the ECI power pack and take the hose (3) off the check valve (71)
- Bolt bracket of purge line to bracket for ECI ignition system power pack = 8 Nm

6 Remove bracket (2) of the ECI power pack (2)
- Bolt bracket for ECI ignition system power pack to charge air distribution pipe = 8 Nm

7 Remove the throttle valve actuator (M16/6)
8 Unscrew screws (4) from the cable channel (5) on the charge air distribution pipe (6)
- Bolt cable duct to charge air distribution pipe = 8 Nm

9 Remove tie strap (arrow)
10.1 Terminate the electrical plug connector from the right hand refrigerant compressor and tie strap
11 Remove the electrical plug connector from the ECI ignition module, right line of cylinders (N92/1) and ECI ignition module, left line of cylinders (N92/2)
12 Remove the ground connections (7)
- Bolt for ground line on charge air distribution pipe = 8 Nm

13 Unplug the electrical plug connection from the coolant temperature sensor (B11/4)
14 Unplug the electrical plug connection from the pressure sensor after the throttle valve actuator (B28/7)
15 Unplug the electrical plug connection from the charge air temperature sensor (B17/8)
16 Unplug the electrical plug connection from the divert air switchover valve (Y101) and the air pump switchover valve (Y32) on the cylinder head
17 Unplug the electrical plug connection from the charge air regulation pressure transducer (Y31/5) on the cylinder head
18 Unplug the electrical plug connection from the camshaft Hall sender, left line of cylinders (B6/2) and camshaft Hall sender, right line of cylinders (B6/3)
19 Mark plug connections (8) for the injectors
20 Remove the filler neck (9) and water pipe (10) with bracket (11)
- Bolt filler neck for low temperature water circuit to bracket = 8 Nm

21 Place wiring harness to one side.
22 Remove the bracket (12) on the right hand side
- Bolt bracket to cylinder head M7 = 14 Nm

23 Remove the fuel prefeed line (13) from the fuel distribution rail (14)
- Union nut fuel feed line at fuel distributor = 20 Nm

24 Remove the bracket (15) on the left hand side
- Bolt bracket to cylinder head M7 = 14 Nm

25 Lift the fuel distribution rail (14) with injectors oft the charge air distribution pipe (6)
- Check the O-rings on the injectors for damage. Replace the injector if the O-ring is faulty.

NOTE: Installation: Oil the O-rings before installing the fuel distribution rail (14).

- Fuel distributor at charge air distribution pipe = 8 Nm

Inspect
26 Check injectors.
- Diagnosis system STAR DIAGNOSIS

NOTE:
- Defect injectors must be replaced:
- Remove and install injection valves

27 Install in the reverse order