Fuel Rail, Injectors and High Pressure Pump Overview
Fuel Rail, Injectors and High Pressure Pump Overview
• Do not disassemble the high pressure pump!
• If a fuel injector is removed, the Teflon seal for the combustion chamber as well as the O-ring must always be replaced. Refer to => [ Fuel Injector Teflon Seal and Washer ] Fuel Injector Teflon Seal and Washer.
• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.
CAUTION!
For reasons of safety, if the battery has not been disconnected, the fuel pump fuse must be removed before opening the fuel supply system as the fuel pump will be activated by the driver door contact switch. Fuse assignment.
The fuel pressure in the high pressure pipe can be up to 120 bar! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening the fuel pipe, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts.
1 Seal
2 Cylinder 1 Fuel Injector (N30)
• Cylinder 3 fuel injector (N32).
• Cylinder 5 fuel injector (N83).
• Removing and installing, refer to => [ Fuel Injectors ] Fuel Injectors.
• The long fuel injectors for cylinders 1, 3 and 5 must not be separated.
3 Spring Element
• Replace every time the fuel rail is removed.
• Ensure the element is securely seated.
4 Support Washer
• Replace if damaged, refer to => [ Fuel Injector Teflon Seal and Washer ] Fuel Injector Teflon Seal and Washer.
5 Seal
• Replace
• Before installing, lubricate with clean engine oil.
6 Bolt
• 30 Nm + 90° (1/4) additional turn.
• Replace
• Tighten uniformly, starting from the inside working toward the outside.
7 Fuel Rail
• For cylinders 1, 3 and 5.
• Always replace the fuel injector spring elements before installing.
• Tighten the bolts uniformly, starting from the inside working toward outside.
8 Fuel Supply Hose
• From the fuel tank.
• With a mount for the low fuel pressure sensor (G410).
• Replace the fuel hose if it is removed from the fuel rail. It is damaged when it is removed from the ridged connections.
9 Pressure Relief Valve
• Lightly lubricate the O-rings with clean engine oil before installing.
• Replace the removed valve.
• Press in by hand using 8 mm hex wrench.
10 Cap
• 22 Nm
11 Low Fuel Pressure Sensor (G410)
• 15 Nm
12 High Pressure Fuel Line
• 28 Nm
• Fuel pressure in the high pressure line can be up to 120 bar! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening the union nuts, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts.
• To loosen and tighten the union nuts, counter hold the connection on the high pressure pump using a wrench.
• Before installing: tighten the connections on the high pressure pump to 40 Nm.
• Do not install when under tension.
• To install, first tighten the union nuts by hand.
13 Low Pressure Fuel Hose
• Between the high pressure pump and fuel rail.
• Always replace the fuel hose because it is damaged when it is removed from the ridged connections.
14 Spring Clamps
15 Bolt
• 8 Nm
16 High Pressure Pump
• With the fuel pressure regulator valve (N276).
• To loosen and tighten the fuel lines, counter hold the connection using a wrench.
• Removing and installing, refer to => [ High Pressure Pump ] High Pressure Pump.
• Before installing the fuel lines, first tighten the connection for fuel lines:
High pressure line connection: 40 Nm.
Low pressure line connection: 28 Nm.
17 Pump Plunger
• Lubricate the O-rings with clean engine oil before installing.
• Note the installed position.
18 Fuel Pressure Sensor (G247)
• 22 Nm
• Checking, refer to => [ Fuel Pressure Sensor, Checking ] Fuel Pressure Sensor, Checking.
• Before installing, lubricate the front sealing point and threads with clean engine oil.
19 Fuel Rail
• For cylinders 2, 4 and 6.
• Tighten the bolts uniformly, starting from the inside working toward the outside.
• Removing and installing, refer to => [ Lower Intake Manifold with Fuel Rail ] Lower Intake Manifold with Fuel Rail.
20 Cylinder 2 Fuel Injector (N31)
• Cylinder 4 fuel injector (N33).
• Cylinder 6 fuel injector (N84).
• Removing and installing, refer to => [ Fuel Injectors ] Fuel Injectors.
21 Connecting Pipe
• 28 Nm
• Do not install when under tension.
• To install, first tighten the union nuts by hand.