Fuel Pump: Service and Repair

243019 Removing And Installing Fuel Ring Pipe

Preliminary work for removing fuel ring pipe

DANGER: Incorrect raising of the vehicle Damage to person or property caused by the car falling down.
- Raise the vehicle at the prescribed jacking points.

1. Place protective covers on the vehicle to avoid damaging the body.
2. Disconnect battery ground lead.
3. Remove engine compartment lid.
4. Remove air-cleaner element.
5. Remove rear underbody cover.

Removing fuel ring pipe

DANGER: Fuel can escape when fuel line is disconnected.
- Risk of fatal injury.
- Damage to skin.

- Do not work on fuel system if engine is hot.
- Do not smoke, avoid fire and naked flames.
- Wear fuel-resistant protective gloves and goggles.
- Attach warning sign to vehicle in a clearly visible position.

1. Release and disconnect fuel lines -arrow-. Collect emerging fuel in a suitable container.
2. Unclip fuel line from the bracket -1-.

Fuel Line:

3. Disengage shift and selector cables or selector lever cable (Tiptronic) and place on the protective cover for the luggage-compartment lid.

View of shift and selector cables for 3.2-litre manual transmission.

Shift And Selector Cables For 3.2 - Litre Manual Transmission:

View of shift and selector cables for 2.7-litre manual transmission.

Shift And Selector Cables For 2.7 - Litre Manual Transmission:

View of Tiptronic selector lever cable.

Tiptronic Selector Lever Cable:

4. Release and pull off cable plugs for fuel injectors -1-.
5. Unscrew two Torx screws (M6 x 10) -2- on the fuel gallery.

Left Fuel Gallery:

Right Fuel Gallery:

6. Pull fuel injectors with fuel gallery out of the bores in the intake-air distributor or intake pipe support.
7. Pull out fuel ring pipe -arrow- between intake-air distributor and body.

Fuel Ring Pipe:

8. Guide fuel ring pipe out of the engine compartment.
9. Lever off safety clips -arrow- on fuel injectors.

Fuel Injector Clips:

10. Pull fuel injectors out of the fuel gallery.

Installing Fuel Ring Pipe

1. Replace O-rings -arrows- on the fuel injectors. Lightly grease new O-rings with Optimal MP3.

Fuel Injector:

2. Press fuel injectors into the fuel gallery.
3. Attach safety clips and make sure they are fitted correctly.
4. Position fuel ring pipe in the engine compartment.
5. Press fuel ring pipe -arrow- in between intake-air distributor and body.

Fuel Ring Pipe:

6. Press fuel injectors with fuel gallery into the bores in the intake-air distributor or intake pipe support.
7. Secure fuel gallery with two Torx screws (M6 x 12) -2-.
Tightening torque 7.5 ftlb.
8. Connect cable plug for fuel injectors -1-. The plugs must engage audibly.

Left Fuel Gallery:

Right Fuel Gallery:

9. Engage shift and selector cables or selector lever cable (Tiptronic).

View of shift and selector cables for 3.2-litre manual transmission

Shift And Selector Cables For 3.2 - Litre Manual Transmission:

View of shift and selector cables for 2.7-litre manual transmission

Shift And Selector Cables For 2.7 - Litre Manual Transmission:

View of Tiptronic selector lever cable

Tiptronic Selector Lever Cable:

10. Connect fuel line -arrow-. The connector must engage audibly.
11. Clip fuel line into the bracket -1-.

Fuel Line:

Subsequent Work For Installing Fuel Ring Pipe

1. Install rear underbody cover.
2. Install air-cleaner element.
3. Connect battery ground lead.
4. Carry out an engine test run. Make sure that the fuel ring pipe is sealed properly, especially at the fuel injectors.
5. Install engine compartment lid.
6. Read out fault memory and correct any faults that are present. Erase fault memory.