Fuel Rail: Service and Repair

Fuel Rail

Special tools, testers and auxiliary items required

• Torque Wrench 5-50 Nm (V.A.G 1331)

• Ratchet, Reversible (V.A.G 1331/1)

• Tool Insert, AF 17 (V.A.G 1331/6)

• Socket (T40055)

Removing


• Follow the guidelines for a clean working environment when working on the fuel system. Refer to => [ Fuel System ] Fuel System.

• Always follow these rules before and during work.

- Remove engine cover. Refer to => [ Engine Cover ] Service and Repair.

- Remove the noise insulation from the cylinder head cover.

- Open the union nuts on the high pressure pump - 6 - and on the fuel rail - 1 - and remove the fuel high pressure line.






- Remove the bolts - arrows - for the fuel high pressure line.

- Remove the fuel supply hose - 3 -.

- Open the clamps - arrows - and free up the wiring harness.






- Disconnect the following electrical connectors.






1 Fuel pressure sensor (G247)
2 Fuel pressure regulator valve (N276)
Injector
Glow plugs


• Mark the allocation of the high pressure lines on the cylinder. They must always be re-installed on the same cylinder.

• Note rules of cleanliness for working on the fuel injection system.

• Always seal any open connections with a suitable cover.

- Remove the high pressure line union nuts on the injectors using the (T40055).

- Loosen the union nuts on the fuel rail high pressure lines using the (V.A.G 1331/6).

- Place the removed high pressure lines on a clean cloth.

- Remove both bolts and remove the fuel rail.

Installing

Installation is carried out in the reverse order while noting the following:

- Install the high pressure lines making sure they are free of tension.

• When using the high pressure line again, pay attention to the cylinder marking.

• The high pressure lines can be reused only after the following checks:

• Check the sealing cone on each high pressure line for deformation and cracks.

• The bores for the lines must not be deformed, narrowed or damaged.

• Do not use corroded lines again.

• Tightening specifications, refer to => [ Fuel System Overview ] Fuel System Overview, Diesel