Removing and installing or replacing high-pressure rail (S55 engine)
Special tools required:
- 32 1 270
- 13 0 160
Disconnect NEGATIVE BATTERY TERMINAL (risk of fire due to short circuit on dismantling).
Electric fuel pump starts up automatically when door is opened!
Carry out installation work on fuel system only with coolant temperature below 40°C.
Attention!
Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high speed when the high pressure line is released!
Attention!
Adhere to conditions of absolute cleanliness when carrying out repairs on the high-pressure fuel system.
Introduced contaminants can cause malfunctions in the system!
- Do not allow any dirt particles or foreign bodies to get into the system.
- Remove all traces of contamination before removing lines or separate components.
- Use only lint-free cloths.
- Seal all openings of the fuel system with suitable plugs from set of special tools 32 1 270.
Attention!
When working on the oil, coolant or fuel circuit, you must protect the alternator against dirt contamination.
Cover alternator with suitable materials.
Failure to comply with this procedure may result in an alternator malfunction.
Necessary preliminary work:
- Remove IGNITION COILS .
- Remove CHARGE AIR COOLER .
Recycling:
Fuel escapes when fuel lines are detached.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.
Removal:
Undo high pressure lines (1) with rubber mount (3) on all injectors (2).
Undo high pressure lines (1) at the high-pressure rail (2).
Release positive battery cable from clamp (1).
Release wiring harness from cable channel (2).
Unlock and disconnect plugs (3).
Disconnect plug (1).
Undo screws (2) and remove high-pressure rail (3) in upward direction.
Installation note:
The decoupling elements and sleeves (1) must be replaced before the high-pressure rail is reinstalled.
Installation:
Install high-pressure rail (3), tightening screws (2) hand-tight only in the process.
Attach and lock connector (1).
Connector (1) must engage audibly.
- High pressure rail must still be displaceable on cylinder head.
Screw high pressure lines (1) hand-tight on high-pressure rail (2).
It must be possible to easily release the high pressure lines (1) by hand.
Installation of high pressure lines:
(Same procedure for all pressure lines)
Mount pressure lines (1) hand-tight on injector (2).
When reinstalling lines, lubricate the thread and the nut facing of the ball! When they are installed for the first time the nuts have a coating of lubricant (only effective once). Penetration of lubricant into the fuel-conducting area should be avoided.
Attention!
Connect pressure line (1) without tension only.
To ensure distortion-free installation of the pressure line and to avoid damaging the thread, it must be possible for both nuts to be screwed on easily by hand!
Reinstall rubber mount (3).
Adhere to tightening sequence:
- *1. Tighten screws (1).
Tightening torque 13 53 2AZ .
Secure positive battery cable in clamp (1).
Secure wiring harness at cable channel (2).
Connect and lock connector (3).
Connector (3) must engage audibly.
Adhere to tightening sequence:
- 2. Tighten high pressure lines (1) at high-pressure rail (2).
Tightening torque 13 53 8AZ .
Attention!
Reset special tool in good time in order to avoid bending high pressure lines.
Tighten nuts (1) with special tool 13 0 160.
Adhere to tightening sequence:
- 3. Tighten high pressure lines (1) with rubber mount (3) at injector (2).
Tightening torque 13 53 9AZ .
Required follow-up work:
- Install IGNITION COILS .
- Install CHARGE AIR COOLER .
Assemble engine.
Check fuel system for leak tightness.
Check function of DME.