Fuel Rail: Service and Repair

Removing And Installing Fuel Distributor Pipe

Preliminary work

Ignition is off, ignition key is removed.
1. Remove intake-air distributor.

Component overview

Component Overview:

Removing fuel distributor pipe

DANGER: Danger of poisoning from fuels.
- Gasoline is toxic.
- Inhaling vapours can cause irritation of the mucous membranes and eyes.
- It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
- Only work on the fuel system in well-ventilated rooms.
- Wear protective gloves that are fuel-resistant.
- Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
- Ensure that there is adequate ventilation and extract all fuel vapours.
- Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
- Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
- Pay attention to cleanliness when working on the fuel system.

DANGER: Danger of fire from fuel.
- Keep clear of ignition sources.
- Do not smoke.
- Disconnect battery.
- Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
- Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow engine to cool down.
- Secure the vehicle, e.g. with a warning sign.
- Change any clothing soaked with fuel immediately.
- In case of fire, use CO2 or dry powder fire extinguishers.

NOTE:
- The ignition must be switched off when working on the fuel system.
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurized before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.







1. Release fuel injector connectors -arrows A- and pull them off -arrows B-.







2. Use a screwdriver to press the locking hooks of the cable duct together -arrows A-, then press out in a downward direction -arrow B- and remove the cable duct from the fuel distributor pipe -arrow C-.







3. Clamp the fuel hose in front of the fuel distributor pipe using a hose clamp -2-. Loosen the spring band clamp on the fuel hose using a spring-band pliers -1- and pull off the fuel hose.







4. Loosen threaded joint of fuel distributor pipe -arrows-.
5. Carefully pull fuel distributor pipe out of the cylinder head using both hands and set it down on a clean surface.
6. Remove all fuel injectors.

Installing fuel distributor pipe

NOTE: Sealing rings on fuel injectors must be replaced.

1. Fit all fuel injectors.

NOTE: When installing the fuel distributor pipe, make sure that the fuel injectors do not become tilted.

2. Carefully insert the fuel distributor pipe into the cylinder head using both hands.







3. Tighten the fastening screws on the fuel distribution pipe hand-tight. Tighten fastening screws to the specified tightening torque. Tightening torque 7.5 ft.lb.







4. Fit fuel hose to the connection for the fuel distributor pipe and secure with a spring-band clamp -1-. Loosen and remove clamp -2-.







5. Connect the line for the fuel injectors to the fuel distributor pipe -arrow A- and press it into the brackets -arrows B- until the locking lugs -C- engage audibly.







6. Push connectors onto the fuel injectors -arrows A- until the locking lugs -B- are felt to engage.

Subsequent work
1. Install intake-air distributor.