Fuel Rail with High Pressure Pump and Injectors Overview
Fuel Rail with High Pressure Pump and Injectors Overview
• Do not disassemble the high pressure pump!
• If a fuel injector is removed, then the combustion chamber Teflon(R) seal and the O-ring must always be replaced. Refer to => [ Fuel Injector Teflon(R) Seal and Washer ] Fuel Injector Teflon(R) Seal and Washer.
• Read the safety precautions before starting. Refer to => [ Safety Precautions ] Fuel Supply.
• Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.
For reasons of safety, if the battery has not been disconnected, then 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.
Fuel pressure in the high pressure pipe can be up to 120 bar! Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Before loosening the fuel pipe, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts.
1 Fitting
• 30 Nm
• Note the installation marks.
2 Low Fuel Pressure Sensor (G410)
• 15 Nm
3 Fuel Supply Hose
• From the fuel tank.
• Replace the fuel supply hose if it is removed from the fuel rail. It is damaged when it is removed from the ridged connections.
4 Spring Clamps
• Only use clamps appropriate for the model type.
5 Low Pressure Fuel Hose
• Between the high pressure pump and the fuel rail.
• Always replace the low pressure fuel hose because it is damaged when it is removed from the ridged connections.
• Note the installation marks, refer to => [ Install the new low pressure hose. Pay attention to the installation marks and the position of the spring type clamps. ] High Pressure Pump.
6 Cam Follower
• Lubricate the O-rings with clean engine oil before installing.
• Note the installed position.
7 Seal
• Always replace
• Before installing, lubricate with clean engine oil.
8 High Pressure Pump
• With the fuel pressure regulator valve.
• 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 the fuel lines:
Connection for the high pressure line: 40 Nm.
Connection for the low pressure hose: 28 Nm.
9 Bolt
• 8 Nm
10 O-ring
• Lightly coat the O-rings with clean engine oil before installing.
11 Pressure Relief Valve
• Lightly coat the O-rings with clean engine oil before installing.
• Replace the removed valve.
• Press in by hand using a 8 mm hex wrench.
12 Plug
• 22 Nm
13 Fuel Pressure Sensor (G247)
• 22 Nm
• Checking, refer to => [ Fuel Pressure Sensor, Checking ] Testing and Inspection.
• Before installation, coat the front sealing point and threads with clean motor oil.
14 Fuel Rail
• For cylinders 2, 4 and 6.
• Tighten the bolts uniformly, starting from the inside and working toward the outside.
• Removing and installing, refer to => [ Lower Intake Manifold with Fuel Rail ] Lower Intake Manifold with Fuel Rail.
15 Bolt
• 30 Nm + an additional 90° (1/4) turn.
• Always replace.
• Tighten uniformly, starting from the inside and working toward the outside.
16 O-ring
• Lightly coat the O-ring with clean engine oil before installing.
17 Support Washer
• Replace if damaged. Refer to => [ Fuel Injector Teflon(R) Seal and Washer ] Fuel Injector Teflon(R) Seal and Washer.
18 Spring
• Replace for every removal of the fuel rail.
• Make sure it is tight.
19 Cylinder 2 Fuel Injector (N31)
• Cylinder 4 fuel injector (N33).
• Cylinder 6 fuel injector (N84).
• Removing and installing, refer to => [ Fuel Injectors ] Fuel Injectors.
20 Fuel Rail
• For cylinders 1, 3 and 5.
• The fuel injector springs - item 18 - must be replaced before installation.
• Tighten the bolts uniformly, starting from the inside and working toward the outside.
21 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.
22 Seal
23 High Pressure Fuel Pipe
• 28 Nm
• The fuel pipe must not touch other components!
• To install, first tighten the union nuts by hand.
• Fuel pressure in the high pressure pipe can be up to 120 bar! Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Before loosening the fuel pipe, 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 on the connection of the high pressure pump using a wrench.
• Before installing: First, tighten the connection at the high pressure pump to 40 Nm.
24 Connecting Pipe
• 28 Nm
• The fuel pipe must not touch other components!
• To install, first tighten the union nuts by hand.
• Loosen and tighten using the wrench socket (T10456).