One Piece Intake Manifold
One Piece Intake Manifold
Fuel Rail, Injectors and High Pressure Pump Overview, from 08.07
• 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.
• Read the safety precautions before beginning work. Refer to => [ Safety Precautions ] Fuel Supply.
• 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 pressure by carefully loosening the union nuts.
1 Bolt
• 30 Nm + 90° (1/4) additional turn.
• Replace
• Tighten the fuel rail uniformly, starting from the inside and working toward the outside
2 Fuel Rail
• For cylinders 1, 3 and 5.
• Fuel injector springs - item 11 - must be replaced before installing.
• Tighten uniformly, starting from the inside and working toward the outside.
3 Spring Type Clip
4 Low Fuel Pressure Sensor (G410)
• 15 Nm
5 Fuel Supply Line
• From the fuel tank.
• With an exception for the fuel pressure sensor (G247).
6 Bolt
• 8 Nm
7 Bolt
• 8 Nm
8 Bracket
• For the fuel supply line.
9 O-ring
• Replace
• Before installing, lubricate with clean engine oil.
10 Support Washer
• Replace if damaged, refer to => [ Fuel Injector Teflon Seal and Washer ] One Piece Intake Manifold.
11 Spring
• Replace for every removal of the fuel rail.
• Ensure the spring is securely seated.
12 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.
13 Seal
• Replace
• Before installing, lubricate with clean engine oil.
14 Low Pressure Fuel Hose
• Between the high pressure pump and fuel rail.
• Always replace the fuel hose because it is damaged when it is removed from the ridged connections.
15 Spring Clamps
16 High Pressure Fuel Pipe
• 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 disconnecting the fuel pipe, place a cloth around the connection point. Then release pressure by carefully loosening the union nuts.
• To loosen and tighten the union nut, 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.
17 Connecting Pipe
• 22 Nm
• Do not install when under tension
• To install, first tighten the union nuts by hand.
18 Pump Plunger
• Lubricate the O-rings with clean engine oil before installing.
19 O-ring
• Replace
• Before installing, lubricate with clean engine oil.
20 High Pressure Pump
• With the fuel pressure regulator valve (N276).
• To loosen and tighten fuel lines, counter hold on the connection using a wrench.
• Removing and installing, refer to => [ High Pressure Pump ] One Piece Intake Manifold.
• Before installing the fuel lines, first tighten the connection for the fuel lines:
High pressure line connection: 40 Nm.
21 Bolt
• 10 Nm
22 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.
23 Spring
• Replace for every removal of the fuel rail.
• Ensure the spring is securely seated.
24 Support Washer
• Replace if damaged. Refer to => [ Fuel Injector Teflon Seal and Washer ] One Piece Intake Manifold.
25 O-ring
• Replace
• Before installing, lubricate with clean engine oil.
26 Fuel Rail
• For cylinders 2, 4 and 6
• Fuel injector springs - item 23 - must be replaced before installing.
• Tighten uniformly, starting from the inside and working toward the outside.
27 Bolt
• 30 Nm + 90° (1/4) additional turn
• Replace
• Tighten the fuel rail uniformly, starting from the inside and working toward the outside.
28 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.
29 Cap
• 22 Nm
30 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.
31 O-ring
• Replace
• Before installing, lubricate with clean engine oil.