Removing and Installing Fuel Connection Line
Removing And Installing Fuel Connection Line
Tools
Technical values
Preliminary work
1. Relieve the fuel pressure.
1.1. Pull fuse for fuel pump out of the fuse carrier in the passenger compartment.
1.2. Start the engine and allow to run until it cuts out.
1.3. Re-insert the fuse.
2. Remove engine compartment lid.
3. Disconnect the battery.
4. Remove resonance tube.
5. Remove intake-air distributor.
5.1. Cover intake port openings with adhesive tape or a cloth.
Removing fuel connection line
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.
INFORMATION: Only work on the fuel system when the engine is cold.
1. Observe safety instructions when working on the fuel system.
1.1. Attach or mount a warning sign in a clearly visible position on the vehicle.
Overview of fuel-carrying components on the engine:
2. Pull hydraulic line -1- off the oil/water heat exchanger.
2.1. Drain hydraulic fluid (Pentosin) from the reservoir.
2.2. Place a cloth underneath the connection to collect emerging oil.
2.3. Open the spring band clamp and pull off the hydraulic line.
2.4. Close off the connection on the oil/water heat exchanger and hydraulic hose with stoppers -2-.
INFORMATION:
Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:
- Torx screws: (E..) for external Torx, (T..) for internal Torx.
- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)
Overview of mounting points for fuel connection line
INFORMATION:
- Ensure everything is clean when working on the fuel system.
- Even the smallest particles of dirt can cause problems and damage to the high-pressure system.
3. Remove fuel line.
3.1. Place a clean cloth underneath the screw points of the fuel line to collect emerging fuel.
3.2. Loosen union nuts (a/f 17)-1 to 3-.
3.3. Unscrew external Torx screw (E10, M6 x 12) -4- on the crankcase clamp.
3.4. Unscrew external Torx screw (E10, M6 x 12) -5- on the clamp on the fuel connection line holder.
4. Turn fuel connection line anti-clockwise to remove it and dispose of the cloth.
5. Close off connection points on the fuel connection line with stoppers.
Installing fuel connection line
WARNING:
Leaking fuel supply lines
- Emerging fuel
- Risk of fire
- Perform leak test.
Tool recommendation:
INFORMATION:
- Ensure everything is clean when working on the fuel system.
- Even the smallest particles of dirt can cause problems and damage to the high-pressure system.
1. Remove stoppers from connection points.
2. Fit fuel connection line -6-.
2.1. Lubricate all connection threads and cones with OKS 1700 (Part No. 000.043.207.36).
2.2. Position fuel connection line.
2.3. Tighten union nut (a/f 17)-1- by 2-3 turns with your hand.
2.4. Tighten union nut (a/f 17)-2- by 2-3 turns with your hand.
2.5. Tighten union nut (a/f 17)-3- by 2-3 turns with your hand.
3. Fit clamps.
3.1. Fit external Torx screw (E10, M6 x 12) -4- on the clamp.
3.2. Fit external Torx screw (E10, M6 x 12) -5- on the clamp.
3.3. Tighten the screws. - Tightening torque: 10 Nm (7.5 ft. lbs.)
4. Tighten union nuts on the fuel connection line.
4.1. Tighten union nuts in the specified sequence -1 to 3- using the recommended tool. - Tightening torque: 20 Nm (15 ft. lbs.)
INFORMATION:
- A leak test must always be performed in the high-pressure area after opening the fuel system.
- This is particularly important if components are disassembled and replaced.
- The threaded connections of the fuel lines must be coated with OKS 1700 lubricant (Part no. 000.043.207.36) before being screwed back on again.
- The tightening specifications must be strictly observed.
- Blow residual fuel out of the lines and high-pressure pump (into a fuel-resistant container or cloth) using compressed air before installation.
5. Leak-test the fuel system.
Subsequent work
1. Install intake-air distributor.
2. Install resonance tube.
3. Check intake-air distributor for leaks.
4. Check the power-steering fluid level and top up if necessary.
5. Install engine compartment lid.
6. Connect the battery.