With Two 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 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 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, refer to --> [ Fuel Injector Teflon Seal and Support Washer ] Fuel Injector Teflon Seal and Support Washer.
5 Seal
• 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.
• Always replace the fuel injector spring retainers --> [ (Item 3) Spring retainer ] before installing.
• Tighten uniformly, starting from inside and working toward outside.
8 Fuel supply hose
• From 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 coat O-rings with clean engine oil before installing.
• Replace the removed valve.
• Press in by hand using 8 mm wrench.
10 22 Nm
11 Low fuel pressure sensor (G410)
• 15 Nm.
12 High pressure fuel pipe
• 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 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 high pressure pump to 40 Nm.
• Do not install when under tension.
• To install, first tighten 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 8 Nm
16 High pressure pump
• With fuel pressure regulator valve (N276).
• To loosen and tighten fuel lines, counter hold on connection using a wrench.
• Removing and installing, refer to --> [ High Pressure Pump ] High Pressure Pump.
• Before installing fuel lines, first tighten connection for fuel lines:
Connection for high pressure line: 40 Nm.
Connection for low pressure line: 28 Nm.
17 Lifter
• Lubricate O-rings with clean engine oil before installing.
• Note installation position.
18 Fuel pressure sensor (G247)
• 22 Nm.
• Checking, refer to --> [ Fuel Pressure Sensor, Checking ] Fuel Pressure Sensor, Checking.
• Before assembly, coat front sealing point and threads with clean motor oil.
19 Fuel rail
• For cylinders 2, 4 and 6.
• Tighten uniformly, starting from inside and working toward 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 Injector ] Fuel Injector.
21 Connecting pipe
• 28 Nm.
• Do not install when under tension.
• To install, first tighten union nuts by hand.