With One Piece Intake Manifold
Fuel Rail with High Pressure Pump and Injectors Assembly Overview
• Do not disassemble the high pressure pump!
• If a fuel injector is removed, Teflon sealing ring of combustion chamber as well as O-ring must always be replaced. Refer to --> [ Fuel Injector Teflon Seal and Support Washer ] Fuel Injector Teflon Seal and Support Washer.
• Read safety precautions before beginning work. Refer to --> [ Safety Precautions ] Safety Precautions.
• Observe the rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.
CAUTION!
For reasons of safety, if the battery has not been disconnected, the Fuel Pump (FP) fuse must be removed before opening the fuel supply system as the FP will be activated by the driver's door contact switch.
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 fuel pipe, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts.
1 Seal
• Replace.
• Before installing, lubricate with clean engine oil.
2 Cylinder 1 fuel injector (N30)
• Cylinder 3 fuel injector (N32).
• Cylinder 5 fuel injector (N83).
• Removing and installing, refer to --> [ Fuel Injector ] Fuel Injector.
• The long fuel injectors for cylinders 1, 3 and 5 must not be separated.
3 Spring retainer
• Replace for every removal of the fuel rail.
• Ensure seated tightly.
4 Support washer
• Replace if damaged.
5 O-ring
• Replace.
• Before installing, lubricate with clean engine oil.
6 30 Nm + 90° (1/4 turn) additional turn
• Replace.
• Tighten fuel rail uniformly, starting from inside and working toward outside.
7 Fuel rail
• For cylinders 1, 3 and 5.
• Spring retainers for fuel injectors must always be replaced before installing --> [ (Item 3) Spring retainer ].
• Tighten uniformly, starting from inside and working toward outside.
8 From fuel tank
9 Fuel supply hose, 22 Nm
• To loosen and tighten union nut, counter hold on supply line of fuel rail using a wrench.
10 Pressure relief valve
• Replace the removed valve.
• Press in by hand using 8 mm wrench.
• Lightly coat O-rings with clean engine oil before installing.
11 22 Nm
12 High pressure fuel line, 28 Nm
• Fuel pressure in 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 fuel lines, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts.
• To loosen and tighten union nut, counter hold on connection of high pressure pump using a wrench.
• Before installing: First tighten connection at the high pressure pump to 40 Nm.
• Do not install when under tension.
• To install, first tighten union nuts by hand.
13 Low pressure fuel line, 27 Nm
• To loosen and tighten union nut, counter hold on connection of high pressure pump using a wrench.
• Before installing: First tighten connection at the high pressure pump to 28 Nm.
• Do not install when under tension.
• To install, first tighten union nuts by hand.
14 Low fuel pressure sensor (G410), 15 Nm
• Before assembly, coat front sealing point and threads with clean motor oil.
15 10 Nm
16 High pressure pump
• With fuel pressure regulator valve (N276)
• To loosen and tighten fuel lines, counter hold on connection using a wrench.
• Before installing fuel lines, first tighten connection for fuel lines:
• Connection for high pressure line: 40 Nm.
• Connection for low pressure line: 28 Nm.
• Removing and installing, refer to --> [ High Pressure Pump ] High Pressure Pump.
17 Lifter
• Lubricate O-rings with clean engine oil before installing.
18 Fuel pressure sensor (G247)
• 22 Nm.
• Before assembly, coat front sealing point and threads with clean motor oil.
• Checking, refer to --> [ Fuel Pressure Sensor, Checking ] Fuel Pressure Sensor, Checking.
19 Fuel rail
• For cylinders 2, 4 and 6.
• Spring retainers for fuel injectors must always be replaced before installing --> [ (Item 3) Spring retainer ].
• Tighten uniformly, starting from inside and working toward outside.
20 Cylinder 2 fuel injector (N31)
• Cylinder 4 fuel injector (N33).
• Cylinder 6 fuel injector (N84).
• Removing and installing, refer to --> [ Fuel Injector ] Fuel Injector.
21 Connecting line, 28 Nm
• Do not install when under tension.
• To install, first tighten union nuts by hand.