Two Piece Intake Manifold

Fuel Rail, High Pressure Pump And Injectors Assembly Overview

NOTE:
- Do not disassemble high pressure pump.
- If a fuel injector is removed, Teflon sealing ring of combustion chamber as well as O-ring must always be replaced.
- Read safety precautions before beginning work.
- Observe the rules for cleanliness.

CAUTION:
- For reasons of safety, if the battery has not been disconnected, Fuel Pump (FP) fuse must be removed before opening the fuel supply system as the FP will be activated by the drivers door contact switch. Fuse assignment Electrical Wiring Diagrams, Troubleshooting and Component Locations.
- Fuel pressure in 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 - 30 Nm + 90 degrees ( 1/4 turn) additional turn
- Replace
- Tighten fuel rail uniformly, starting from inside and working toward outside
2 - Fuel rail
- For cylinders 1, 3 and 5
- Tighten uniformly, starting from inside and working toward outside
3 - Spring-type clip
4 - Low fuel pressure sensor G410, 15 Nm
5 - Fuel supply hose
- From fuel tank
- With a mount for the low fuel pressure sensor G410
- Always replace the fuel hose because it is damaged when it is removed from the ridged connections.
6 - 8 Nm
7 - 8 Nm
8 - Bracket
- For fuel hose
9 - O-ring
- Replace
- Before installing, lubricate with clean engine oil
10 - Support washer
- Replace if damaged.
11 - Spring element
- Replace for every removal of the fuel rail
- Ensure seated tightly
12 - Cylinder 1 fuel injector N30
- Cylinder 3 fuel injector N32
- Cylinder 5 fuel injector N83
- The "long" fuel injectors for cylinders 1, 3 and 5 must not be separated.
13 - Seal
- Replace
- Before installing, lubricate with clean engine oil
14 - 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.
15 - Spring clamps
16 - High pressure fuel pipe, 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 high pressure pump to 40 Nm.
- Do not install when under tension
- To install, first tighten union nuts by hand.
17 - Connecting pipe, 28 Nm
- Do not install when under tension
- To install, first tighten union nuts by hand.
18 - Lifter
- Lubricate O-rings with clean engine oil before installing
19 - O-ring
- Replace
- Before installing, lubricate with clean engine oil
20 - 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
21 - 10 Nm
22 - Cylinder 2 fuel injector N31
- Cylinder 4 fuel injector N33
- Cylinder 6 fuel injector N84
23 - Spring element
- Replace for every removal of the fuel rail
- Ensure seated tightly
24 - Support washer
- Replace if damaged.
25 - O-ring
- Replace
- Before installing, lubricate with clean engine oil
26 - Fuel rail
- For cylinders 2, 4 and 6
- Tighten uniformly, starting from inside and working toward outside
27 - 30 Nm + 90 degrees ( 1/4 turn) additional turn
- Replace
- Tighten fuel rail uniformly, starting from inside and working toward outside
28 - Fuel pressure sensor G247, 22 Nm
- Before assembly, coat front sealing point and threads with clean motor oil.
29 - 22 Nm
30 - Pressure relief valve
- Lightly coat O-rings with clean engine oil before installing
- Replace the removed valve
- Press in by hand using 8 mm hex wrench
31 - O-ring
- Replace
- Before installing, lubricate with clean engine oil