944S
WORK PROCEDURE BPorsche 944S - Replacement of Fuel Rail
1. Open front hood.
2. Install fender covers.
3. Note radio presets and, if applicable, theft code.
4. Disconnect battery negative cable and insulate battery post.
5. If car is equipped with cruise control, remove bracket for servo-motor cable.
Note:
Remove the aluminum washer between bracket and intake manifold.
6. Remove fuel rail cover.
7. Remove the three cable straps which secure the DME wiring harness and fuel rail.
8. Disconnect the electrical connectors from the four fuel injectors.
9. Place rags under fuel rail in the area of the test connection and under fuel hoses which connect to the fuel rail, to absorb possible fuel spillage.
10. Remove fuel filter cap.
11. Remove the cap nut for the test connection on the fuel rail using a 19 mm open end wrench, counter holding with a 12 mm open end wrench and remove the sealing ball.
12. Remove fuel return hose clamp on the pressure regulator and remove hose from pressure regulator.
13. Disconnect fuel supply line from fuel rail using a 19 mm open wrench and a 17 mm open wrench to counter hold.
14. Remove both 6 mm bolts which attach the pressure damper from intake manifold (arrows 1 and 2).
Note:
Keep both aluminum washers which are located between pressure damper and intake manifold.
15. Remove the three 6 mm bolts which hold the fuel rail.
16. Remove vacuum hoses from fuel pressure regulator and damper.
17. Pull out the fuel rail together with the four fuel injectors (B).
18. Remove the three aluminum spacers washers from between fuel rail and intake manifold.
19. Secure fuel rail in a vise, using copper jaws.
20. Remove the injector clips and pull out injectors.
21. Remove fuel supply hose from the pressure damper (B), using an open end 19 mm wrench, counter holding with a 24 mm open end wrench the pressure damper.
22. Remove fuel return hose from the pressure damper, using an open end 19 mm wrench, counter holding with a 15 mm open wrench the pressure damper and remove the pressure damper.
23. Remove the two 6 mm bolts which hold the pressure regulator (C) from the fuel rail and take off the regulator.
24. Remove O-ring from the pressure regulator and install new o-ring, Part Number 000 043 142 00. Lubricate 0-ring lightly with engine oil.
25. Remove old fuel rail from the vise and replace with new fuel rail, Part Number 944 110 080 13. Secure the new fuel rail in the vise lightly.
26. Push the pressure regulator (C) into the new fuel rail and secure it with the 6 mm bolts. Tightening torque: 10 N-m (7.2 ft.lbs.).
27. Install pressure damper (B), secure fuel supply hose with a 19 mm open end wrench, counter holding with a 24 mm open end Wrench. Tightening torque: 30 N-m (21.6 ft.lbs.).
28. Reinstall fuel return hose to pressure damper, using a 19 mm open end wrench and counter holding with a 15 mm open end wrench. Tightening torque: 30 N-m (21.6 ft.lbs.).
29. Remove the upper and lower O-rings on the fuel injectors (arrow 1). Lubricate new O-rings slightly with engine oil and install on injectors.
Note:
Watch for the correct installation of the sealing washer and the lower O-ring (arrow 2).
30. Push the injectors into the new fuel rail and secure with the clips.
31. Install the three aluminum spacers on the intake manifold, using a little grease to hold them in place.
32. Remove fuel rail from the vise and install together with fuel injectors onto intake manifold, assuring the correct position of the electrical connection of the fuel injectors.
33. Install the three 6 mm bolts, which secure the fuel rail to the intake manifold. Tightening torque: 10 N-m (7.2 ft.lbs.).
Note:
The three aluminum washers must be installed between the fuel rail and intake manifold!
34. Reinstall pressure damper with the two 6 mm bolts. Tightening torque: 10 N-m (7.2 ft.lbs.).
Note:
The two aluminum washers must be installed between the damper bracket and intake manifold.
35. Reinstall the vacuum hoses on the pressure regulator and pressure damper.
Note:
Do NOT use any lubricant!
36. Install the fuel return hose on the pressure regulator, secure with hose clamp.
Note:
Do NOT use any lubricant!
37. Reinstall fuel supply hose using a 19 mm open end wrench and counter holding it with a 17 mm open end wrench. Tightening torque: 30 N-m (21.6 ft.lbs.).
38. Install sealing ball and cap nut on fuel rail with a 19 mm open end wrench, counter holding it with 12 mm open end wrench. Tightening torque: 22 N-m (17 ft.lbs.).
39. Install cable connectors on fuel injectors.
40. Secure DME wiring harness on fuel rail with three cable straps, Part Number N 020 904 4.
41. If car is equipped with cruise control, reinstall cable bracket for servo-maker. Assure that cable is not twisted and free moving. Tightening torque: 10 N-m (7.2 ft.lbs.).
Note:
The aluminum spacer must be installed between the bracket and the intake manifold.
42. Reconnect battery.
43. Start engine and check for fuel leaks. If no leak, shut off engine and proceed to # 45. If a fuel leak is noticed, shut off engine, correct the leakage and proceed to # 44 (possible leak points indicated by arrows 6, 7, 8, 9, 10 and 11).
44. Restart engine and ensure that fuel leak is corrected, shut off engine, and proceed to # 45. However, if fuel leak persists, shut off engine and repeat # 43.
45. Reinstall fuel rail cover.
46. Reinstall fuel filler cap.
47. Identify completion of performed Recall on the vehicle by marking the forward portion of the fuel rail cover with a WHITE PAINT DOT. Ensure that the spot to be marked is free of grease and the paint adheres to the cover.
48. Remove fender covers.
49. Close front hood.
50. Reset clock, reset radio theft code (if applicable) and station presets.