One Piece Intake Manifold
One Piece Intake Manifold
Fuel Rail, Injectors and High Pressure Pump Overview, through 07.07
• Do not disassemble the high pressure pump!
• If a fuel injector is removed, the combustion chamber Teflon seal and O-ring must be replaced. Refer to => [ Fuel Injectors ] One Piece Intake Manifold.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Multiport Fuel Injection.
CAUTION!
Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
The fuel pressure in the high pressure pipe can be up to 120 bar! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the fuel pipe, place a cloth around the connection point. Then release the pressure by carefully loosen the union nuts.
1 Seal
• Replace
• Before installing, lubricate with clean engine oil.
2 Cylinder 1 Fuel Injector (N30)
• Cylinder 3 fuel injector (N32).
• Cylinder 5 fuel injector (N83).
• Removing and installing, refer to => [ Fuel Injectors ] One Piece Intake Manifold.
• The long fuel injectors for cylinders 1, 3 and 5 must not be separated.
3 Spring
• Replace for every removal of the fuel rail.
• Ensure the spring is securely seated.
4 Support Washer
• Replace if damaged. Refer to => [ Fuel Injector Teflon Seal and Washer ] One Piece Intake Manifold.
5 O-ring
• Replace
• Before installing, lubricate with clean engine oil.
6 Bolt
• 30 Nm + 90° (1/4) additional turn.
• Replace
• Tighten the fuel rail uniformly, starting from the inside and working toward the outside.
7 Fuel Rail
• For cylinders 1, 3 and 5.
• Fuel injector springs - item 3 - must be replaced before installing.
• Tighten uniformly, starting from the inside and working toward the outside.
8 Pressure Relief Valve
• Lightly lubricate the O-rings with clean engine oil before installing.
• Replace the removed valve.
• Press in by hand using a 8 mm hex wrench.
9 Cap
• 22 Nm
10 High Pressure Fuel Line
• 22 Nm
• Fuel pressure in the high pressure line can be up to 120 bar! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before loosening the fuel line, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts.
• To loosen and tighten the union nuts, counter hold on the connection of the high pressure pump using a wrench.
• Before installing: tighten the connection on the high pressure pump to 40 Nm.
• Do not install when under tension.
• To install, first tighten the union nuts by hand.
11 Low Pressure Fuel Line
• 27 Nm
• To loosen and tighten the union nuts, counter hold on the connection of the high pressure pump using a wrench.
• Before installing: tighten the connection on the high pressure pump to 28 Nm.
• Do not install when under tension
• To install, first tighten the union nuts by hand.
12 Low Fuel Pressure Sensor (G410)
• 15 Nm
13 Bolt
• 10 Nm
14 High Pressure Pump
• With the fuel pressure regulator valve (N276).
• To loosen and tighten the fuel lines, counter hold on the connection using a wrench.
• Before installing the fuel lines, first tighten the connection for the fuel lines:
• Removing and installing, refer to => [ High Pressure Pump ] One Piece Intake Manifold.
High pressure line connection: 40 Nm.
Low pressure line connection: 28 Nm.
15 Pump Plunger
• Lubricate O-rings with clean engine oil before installing.
16 Fuel Pressure Sensor (G247)
• 22 Nm
• Before assembly, lubricate the front sealing point and threads with clean motor oil.
• Checking, refer to => [ Fuel Pressure Sensor, Checking ] One Piece Intake Manifold.
17 Fuel Rail
• For cylinders 2, 4 and 6.
• Fuel injector springs - item 3 - must be replaced before installing.
• Tighten uniformly, starting from the inside and working toward the outside.
18 Cylinder 2 Fuel Injector (N31)
• Cylinder 4 fuel injector (N33).
• Cylinder 6 fuel injector (N84).
• Removing and installing, refer to => [ Fuel Injectors ] One Piece Intake Manifold.
19 Connecting Line
• 22 Nm
• Do not install when under tension.
• To install, first tighten the union nuts by hand.
20 Fuel Supply Line
• 22 Nm
• From the fuel tank
• To loosen and tighten the union nut, counter hold on the supply line fitting on the fuel rail using a wrench.