Checking Fuel Pump Capacity, 4-Cyl.
| WARNING | Checking the capacity of the fuel pump involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work |
- Work only in a well-ventilated area. If approved equipment for the extraction of fuel vapour is available, be sure to use it.
- Wear suitable gloves. Prolonged contact with fuel can cause skin irritation or dramatist.
- Keep a class BE fire extinguisher near at hand. Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.
- No smoking anywhere in the vicinity
- Wear protective goggles.
Scheme 1
Scheme 2
Scheme 3
- Remove the engine cover.
- Extract the fuel pump fuse no. 19 with the engine running. Switch off the ignition when the engine has stopped.
- Detach the return line from the fuel rail. Use 83 95 261 Tools, Fuel line. Use flat pliers to remove the rubber seal from the quick-release coupling. IMPORTANT: In all work involving disconnection of the fuel line's quick-release couplings, great care should be taken to avoid damaging the sealing surface of the male coupling half. If the male coupling half is extremely dirty it should be cleaned before disconnection. Also clean the sealing surface after disconnection, if necessary. Use a soft cloth. Lubricate the male coupling half before fitting.
- Connect the adapter with the hose 83 94 744 Adapter, fuel pressure testing to the return line from the fuel rail. Place the hose opening in a collecting receptacle.
- Run the fuel pump for 30 seconds, using the diagnostics tool. During 30 seconds of operation the pump should deliver at least 700 ml of fuel to the receptacle.
Checking Fuel Pump Capacity, V6.
| WARNING | Checking the capacity of the fuel pump involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work |
- Work only in a well-ventilated area. If approved equipment for the extraction of fuel vapour is available, be sure to use it.
- Wear suitable gloves. Prolonged contact with fuel can cause skin irritation or dramatist.
- Keep a class BE fire extinguisher near at hand. Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.
- No smoking anywhere in the vicinity
- Wear protective goggles.
Scheme 4
Scheme 5
Scheme 6
- Reduce fuel pressure by removing fuel pump fuse no. 19 while the engine is idling. Turn off the ignition once the engine has stopped and replace the fuse.
- Remove the engine cover.
- Detach the return line from the fuel rail.
- Connect the adapter with the hose 83 94 744 Adapter, fuel pressure testing to the return line from the fuel rail. Place the hose opening in a collecting receptacle.
- Run the fuel pump with the diagnostic tool for 30 seconds. During 30 seconds of operation the pump should deliver at least 700 ml of fuel to the receptacle.
Checking Injector Flow Capacity
| WARNING | Removal of the fuel pressure regulator involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work |
- Work only in a well-ventilated area. If approved equipment for the extraction of fuel vapour is available, be sure to use it.
- Wear suitable gloves. Prolonged contact with fuel can cause skin irritation or dramatist.
- Keep a class BE fire extinguisher near at hand. Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits.
- No smoking anywhere in the vicinity
- Wear protective goggles.
| IMPORTANT | Scrupulous cleanliness is of the utmost importance when working on the fuel rail and injectors. Thoroughly clean the injectors, fuel rail and intake manifold and blow dry with compressed air. |
Scheme 7
Scheme 8
- Remove the fuel rail according to Fuel rail with injectors, 4-cyl. or Fuel rail with injectors, V6.
- Fit a transparent hose onto the nozzle. This hose should be about 40 cm long and have an inside diameter of 15 mm.
- Place the end of the hose in a receptacle or measuring flask.
- Connect each injector to its proper connector.
- Start the fuel pump by connecting diagnostics cable 83 93 886 Lead fault diagnosis, LH-system to the upper pin on fuse no. 8 and the lower pin of fuse no. 19.
- Perform a flow capacity test with the diagnostic tool. The diagnostic tool then activates the injector concerned with battery voltage for exactly 30 seconds.
- Check the quantity of fuel against the table below.
- Replace any defective injectors.
- Attach fuel rail according to Fuel rail with injectors, 4-cyl. or Fuel rail with injectors, V6.
| Engine type | | Flow capacity | | Maximum permissible Difference between injectors |
|---|
| B235E | Ml/30s | 176 +/- 7 | Ml | 14 |
| B205E | Ml/30s | 127 +/- 5 | Ml | 10 |
| B308E | Ml/30s | 109 +/- 4 | Ml | 8 |
FUEL RAIL WITH INJECTORS DESCRIPTIONS
Tightening Torques
| Torque (Nm) | Torque (lbf ft) |
|---|
| Filler pipe, hose clips | 4 | 3 |
| Filler pipe, plastic screw | 1,5 | 1 |
| Fuel filter, banjo fitting | 21 | 16 |
| Fuel pump, screw ring | 75 | 55 |
| Fuel rail, V6 | 8 | 6 |
| Upper intake manifold, V6 | 20 | 15 |
