Fuel Rail: Service and Repair

Fuel rail with injectors

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:
- Work only in a well-ventilated area. If approved equipment for the extraction of fuel vapors is available, be sure to use it.
- Wear suitable gloves. Prolonged contact with fuel can cause skin irritation or dermatitis.
- Keep a class BE fire extinguisher near at hand. Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.
- No smoking anywhere in the vicinity,
- Wear protective goggles.






To Remove

Important
Scrupulous cleanliness is of the utmost importance when working on the fuel rail and injectors. Thoroughly clean the injectors, fuel rail and intake manifold and blow dry with compressed air.

1 Extract fuse No. 19 with the engine running.
2 Switch off the ignition when the engine has stopped.
3 Detach the crankcase ventilation hoses.
4 Unscrew the solenoid valve (2 bolts) and its connector. Move the solenoid valve aside.
5 Remove the dipstick with filler funnel (2 bolts) and plug the tube.







6 Detach and bend aside the throttle cable with holder (3 bolts). Disconnect the throttle cable from the throttle spindle.
7 Slacken the turbocharger delivery pipe retaining screw in the cylinder head.
8 Undo the hose clips and turn the hose elbow upwards.







9 Slacken the wiring holder's upper front bolt.
10 Remove the rear bolt.
11 Lift up the wiring holder and bend it rearwards.







12 Unplug the following connectors: ignition discharge module, injectors, manifold absolute pressure sensor, mass air flow sensor and turbo pressure sensor.
13 Disconnect the wiring and bend it aside. 2 clips on the raid and 6 on the crankcase ventilation pipe.

Important
Secure each injector clip with a narrow cable tie. Make sure that it is correctly fitted and then tighten it. If this is not done, the injectors could come loose from the fuel rail during the flow test.

14 Clean the area round the injectors with compressed air.
15 Remove the fuel rail's 2 retaining bolts.
16 Disconnect the pressure regulator's vacuum hose.
17 Carefully prise the rail loose using 2 pry bars, screwdrivers or the like.
18 Carefully lift the rail up and away.
19 Plug the nozzle orifices.

To fit
lubricate the injector O-rings with acidfree vaseline before fitting them in place.
Fit in reverse order.
Adjust the throttle cable.

Important
Check that the right connector is plugged into the right injector as indicated on the wiring. Spray all connectors with contact cleaner Kontakt 61, part No. 30 04 520, before fitting.