Attention:
- When working on the fuel tank or fuel lines, smoking or using open flames in the workplace is not permitted.
- Be careful not to spill fuel when disconnecting the fuel connectors.
- When performing work, use leak-resistant nitrile gloves and goggles with side protection.
- To prevent contaminants from entering the fuel system circuit, use plugs to seal the openings of disconnected components.
- To avoid corrosion or damage, measures must be taken to protect surfaces that may come into contact with leaking fuel.
Checking the fuel supply
1. Loosen the oil filler neck bolt.
2. Remove the oil filler neck from the engine.
3. Disconnect the fuel supply line connector from the fuel rail.
4. Install the T-shaped connector to measure the fuel pressure (Mot. 1311-08).
5. Connect a hose of sufficient length to the T-piece to drain the fuel from the pump into the tank.
6. Place the end of the hose into a graduated measuring cylinder (2000 ml).
7. Remove the cover from the engine compartment fuse and relay box.
8. Remove the relay (1).
9. Close the circuit across the relay to supply power to the electric fuel pump.
Note: Fuel supply should be 80 - 120 l/hour.
10. Install the fuel pump relay.
11. Install the cover on the engine compartment fuse and relay box.
12. Remove the T-shaped connector (Mot. 1311-08).
13. Connect the fuel supply line connector to the fuel rail.
14. Install the oil filler neck onto the engine.
Checking fuel pressure
1. Prepare a fuel pressure gauge with an adapter (Mot. 1311-01) and T-shaped connecting element (Mot. 1311-08).
2. Loosen the oil filler neck bolt.
3. Remove the oil filler neck from the engine.
4. Disconnect the fuel supply line connector from the fuel rail.
5. Install the T-shaped connector to measure the fuel pressure (Mot. 1311-08) to the fuel supply line.
6. Connect the fuel pressure gauge hose to the T-piece.
7. Connect the T-piece to the fuel rail.
8. Install the engine oil filler neck.
9. Start the engine.
10. Measure the fuel pressure. It should be 3.5 bar and constant.
Note: It takes a few seconds to obtain the correct fuel rail pressure value
11. Turn off the engine.
12. Remove the oil filler neck again.
13. Remove the T-shaped connector.
14. Connect the fuel supply line connector to the fuel rail.
15. Install the oil filler neck onto the engine.
Removal and installation the fuel rail with injectors
Caution: Do not test fuel injectors by directly applying 12V voltage.
Note: Each power supply component requires a corresponding plug.
Removal the fuel rail with injectors
1. Disconnect the negative battery terminal.
2. Remove the air filter unit
3. Remove the intake manifold and place it on a workbench.
4. Disconnect the injection control wires.
5. Loosen the bolts (1) and remove the fuel rail assembly.
6. Disconnect the injection control wiring.
7. Remove the clamps (2) and remove the fuel injectors (3).
Installation of fuel rail with injectors
Note: Always replace the seals and fuel injector retaining clips with new ones after each removal.
1. Install fuel injectors with clamps on the fuel rail.
2. Install the injection control wiring.
3. Install the fuel rail onto the intake manifold.
4. Connect the injection control wiring.
5. Further installation is carried out in the reverse order of removal.
6. Using the diagnostic tool, perform the calibration and initialization procedure for the engine ECU and fuel injectors.