Injectors

Injectors

WARNING: Removal of the fuel pressure regulator 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.

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.

To remove





1 Extract fuse No. 19 with the engine running.
2 Switch off the ignition when the engine has stopped. The put the fuse back in place.
3 Remove the engine cover.
4 Detach the crankcase breather hose.
5 Remove the dipstick with filler funnel (2 bolts) and plug the tube.





6 Disconnect and bend aside the throttle cable with holder (3 bolts). Detach the throttle cable from the throttle body's pedal arm.
7 Slacken the turbocharger delivery pipe retaining screw in the cylinder head.
8 Loosen the hose clips and twist up the hose bend next to the throttle body.





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 these connectors: ignition discharge module, injectors, manifold absolute pressure sensor, mass air flow sensor and charge air control valve.
13 Disconnect the wiring from the fuel rail and bend it aside.

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 pry loose the rail using 2 crowbars or the like.
18 Carefully lift the rail up and away.
19 Plug the nozzle holes to prevent the ingress of dirt.

To fit
Inspect the injector O-rings and smear them with non-acidic petroleum jelly (Vaseline) before refitting.
Fit in reverse order.
Adjust the throttle cable.
Clear diagnostic trouble codes

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.