Fuel Rail: Service and Repair
Fuel Rail With Injectors, 4-cyl. (B235E/R)
WARNING
Work involving removal of the fuel rail involves interference with the car fuel system. The following points should therefore be observed in connection with the procedure:
- Ensure good ventilation! If there is approved ventilation for extraction of fuel fumes then this must be used.
- Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation of the skin.
- Have a fire extinguisher class BE at hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.
- Absolutely No Smoking!
- Wear protective glasses.
To remove
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 fuse 19 with the engine running. Turn the ignition key to OFF when the engine has stopped.
3. Undo the hoses for the crankcase ventilation.
4. Take out the dipstick with oil filler pipe end and plug the pipe.
5. Remove the cover and detach the throttle cable from the throttle spindle. Bend the throttle cable and holder to one side.
6. Unplug the connectors for the injectors, ignition discharge module, absolute pressure sensor, mass air flow sensor and the turbo pressure sensor.
7. Slacken the upper bolt of the wiring holder.
8. Remove the lower screws.
9. Lift up the wiring holder and bend it rearwards.
10. Loosen the cable and bend them to one side.
IMPORTANT:
Secure each injector clip with a narrow cable tie. Make sure that it is fitted correctly before tightening. If not, the injectors could come loose from the fuel rail during the flow test.
11. Undo the fuel lines with 83 95 261 Tools, Fuel line.
12. Clean the area round the injectors with compressed air.
13. Disconnect the pressure regulator's vacuum hose.
14. Remove the fuel rail's 2 retaining bolts.
15. Carefully prise loose the rail using 2 pry bars or the like.
16. Carefully lift the rail up and away.
17. Plug the nozzle orifices.
To fit
IMPORTANT:
Make sure the connectors are connected to the correct injectors according to the markings on the cables. It is essential that the injectors be fitted with the connector pointing straight up.
NOTE: Spray the connectors with Contact 61, part no.30 04 520, before connecting them.
1. Lubricate the O-rings on the injectors with acid-free vaseline.
2. Remove the plugs from the injector orifices and fit the fuel rail.
3. Remove the cable ties securing the injector clips.
4. Connect the vacuum hose to the pressure regulator.
5. Connect the fuel hoses and connectors to the fuel injectors.
6. Fit the wiring holder (3 screws)
7. Fit the throttle cable with holder and the cover over the throttle cable. Adjust the throttle cable.
8. Remove the plug and fit the dipstick with filler pipe.
9. Connect the hoses for the crankcase ventilation.
10. Fit the upper engine cover.
Fuel Rail With Injectors, 4 Cyl.
WARNING
Work involving removal of the fuel rail involves interference with the car fuel system. The following points should therefore be observed in connection with the procedure:
- Ensure good ventilation! If there is approved ventilation for extraction of fuel fumes then this must be used.
- Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation of the skin.
- Have a fire extinguisher class BE at hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.
- Absolutely No Smoking!
- Wear protective glasses.
To remove
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.
9. Remove the rear bolt.
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.
To fit
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.