Fuel Rail: Testing and Inspection
WM 243001 Checking fuel distributor pipe (high-pressure system) for leaks
Tools
Technical values
Preliminary work
WARNING
Toxic substances
- Danger of poisoning or suffocation
-> Ventilate the work area well.
-> Never ingest or inhale.
-> Read specific information on the Hazard Sheet.
-> Wear personal protective gear.
WARNING
Highly inflammable or explosive materials
- Danger of fire or explosion
-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.
NOTICE
Dirt on injection system components (intake manifold injection and direct fuel injection system)
- Material damage
- Rough-running engine
- Bad exhaust emissions
-> Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.
-> Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.
-> Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.
-> Only install clean parts. Do not take spare parts out of the packaging until just before installation.
-> Never use compressed air when the system is open. Do not move the vehicle.
WARNING
Leaking fuel supply lines
- Emerging fuel
- Risk of fire
-> Perform leak test.
Information
- Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting.
Information
- 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 depressurised 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.
- After disassembly work on the high-pressure injection system, fit the components to the prescribed torques.
- Visible threaded joints must be inspected for leaks with the engine idling after a test drive.
- For the check to be performed correctly, the components to be checked must not contain any fuel. When dismantling, remove fuel from the lines.
1. Remove rear engine-compartment cover. -> 700219 Removing and installing front trim (engine compartment) - section on "Removing"
2. Pull out fuse for the fuel pump in the central electrical system or disconnect the battery. This ensures that the fuel pump does not start up when a door is opened.
Information
Component overview
Fuel injectors
Fuel distributor pipe
High-pressure pump, turbo engine
High-pressure pump, naturally aspirated engine
Tools and materials
Tools and leak-locating media for the leak test
Tools for leak test
Approved leak-locating gases (test media)
Subsequent work
1. Remove tool setup.
2. Fit the fuel line. To do this, fit the fuel supply line (low pressure) at the marking correctly. Counter while doing this.=> Tightening torque: 35 Nm (26 ftlb.)
3. Fit engine cover. For details, see -> 700219 Removing and installing front trim panel (engine compartment) - section on "Installing"
4. Fit the fuse or connect the battery.
5. Bleed the fuel high-pressure system. -> 2430B1 Filling and bleeding the fuel high-pressure system (includes bleeding fuel distributor pipe) Service and Repair