244019 Removing and installing high-pressure fuel injector (DFI)
WM 244019 Removing and installing high-pressure fuel injector (DFI)
Tools
Technical values
Preliminary work
1. Read out engine control unit fault memory before getting started and print log.
2. Switch off the ignition and all loads when working on the fuel system.
3. Disconnect the battery.
4. Remove intake-air distributor (intake module). => 244619 Removing and installing intake-air distributor on DFI engines - section on "Removing"
5. Remove high-pressure distribution pipe (fuel rail). => 243019 Removing and installing fuel distribution pipe (fuel rail) on DFI engines - section on "Removing"
Information
Component overview
Information
- The high-pressure fuel injectors of the petrol direct-injection system are distinguished from each other by means of colour clips (naturally aspirated engine and Turbo engine). The naturally aspirated engine injector has a blue clip, while the injector for the Turbo engine has a yellow clip. They are visible through a cut-out in the holding-down device.
- Classified high-pressure fuel injectors are installed, depending on the engine number. Two different injectors for naturally-aspirated engines and two different injectors for Turbo engines with different flow rates are used. The colour clips merely differentiate the injectors for naturally aspirated from those for Turbo engines (blue and yellow). As described in the TI => 244000 Replacing high-pressure fuel injector (DFI), the part numbers must be checked when replacing injectors individually. See also Porsche Spare Parts Catalogue.
Fuel injectors
Fuel distribution pipe
Removing high-pressure fuel injector
DANGER
Danger of poisoning from fuels.
-> Gasoline is toxic.
-> Inhaling vapours can cause irritation of the mucous membranes and eyes.
-> It can be carcinogenic. It represents a serious risk to health when inhaled, touched or swallowed over longer periods.
-> Only work on the fuel system in well-ventilated rooms.
-> Wear protective gloves that are fuel-resistant.
-> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapours.
-> Ensure that there is adequate ventilation and extract all fuel vapours.
-> Before opening the fuel lines or fuel hoses, relieve the fuel pressure.
-> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
-> Pay attention to cleanliness when working on the fuel system.
DANGER
Danger of fire from fuel.
-> Keep clear of ignition sources.
-> Do not smoke.
-> Disconnect battery.
-> Danger of fire due to naked flames and sparks, e.g. during welding or grinding work.
-> Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Allow engine to cool down.
-> Secure the vehicle, e.g. with a warning sign.
-> Change any clothing soaked with fuel immediately.
-> In case of fire, use CO2 or dry powder fire extinguishers.
CAUTION
Dirt on injection system components (intake manifold injection and direct fuel injection system)
- Material damage
- Rough-running engine
- Bad exhaust emissions
-> Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.
-> Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.
-> Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.
-> Only install clean parts. Do not take spare parts out of the packaging until just before installation.
-> Never use compressed air when the system is open. Do not move the vehicle.
Information
- Absorb any escaping fuel using a suitable binding material or a cloth.
- Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
- The fuel system must be depressurised before starting work on it.
- Only work on the fuel system in well-ventilated rooms.
- Any seals which have been removed must always be replaced.
- Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors.
Information
The tool numbers refer to the individual parts of the tools in the repair kit T10133 and the supplement set T10133/11-15 (unless indicated otherwise).
Information
- When replacing injectors, always follow the instructions on mileage and bank-specific replacement. => 244055 Replacing DFI high-pressure fuel injector - IMPORTANT.
1. Pull cable plugs off the injectors. -arrows-
Injector cable plugs
2. Remove screw on retainer and remove retainer from the injectors => Retainer for injectors. To do this, use both hands to pull off the retainer against the resistance of the upper damping rings. Tilt carefully back and forth with a pliers if necessary and remove it.
Retainer for injectors
3. Pull injector out of the cylinder head by hand (use a glove.).
If the injector is stuck in the cylinder head due to coking of the injector tips, proceed as follows:
4. Grip injector at the connecting taper at the top using a suitable open-ended wrench and carefully turn the injector back and forth without using force (if any part of the injector body is damaged during removal, the complete injector must be replaced). => Removing injector
Removing injector
5. Bolt impact hammer no. 3 to adapter 9757 -1-.
Impact hammer and puller
6. Fit impact hammer and puller onto the thread of the injector and carefully remove injector by hitting it straight on a number of times. (Remember that if any part of the injector body is damaged during removal, the complete injector must be replaced.) => Impact hammer on injector
Impact hammer on injector
Replacing Teflon sealing ring on high-pressure fuel injector
NOTICE
Incorrect handling of injectors
- Leaks in combustion chamber
-> Teflon sealing rings must always be replaced after removal and before refitting injectors.
-> Do not replace Teflon sealing rings until just before fitting the injector.
-> Install injector immediately after replacing the Teflon sealing ring.
Information
The tool numbers refer to the individual parts of the tools in the repair kit T10133 and the supplement set T10133/11-15 (unless indicated otherwise).
Installation position of Teflon sealing ring: -arrow-
Teflon sealing ring
1. Remove high-pressure fuel injector.
2. Clean fuel injector carefully using a plastic brush (or cloth) and acetone or solvent naphtha. Hold Teflon sealing ring gently using a pointed-nose pliers and carefully pull off Teflon sealing ring -1-. Do not scratch valve body.
Removing Teflon sealing ring
3. Also clean sealing ring groove in the area of the sealing ring. Remove any deposits (coking).
4. Place new sealing ring -2- onto mounting cone no. 5 -1-. Using assembly sleeve no. 6 -3- (knurling facing the sealing ring), push sealing ring gently as far as it will go onto mounting cone no. 5.
Teflon sealing ring on mounting cone
5. Turn assembly sleeve no. 6 -3- around (knurled side now no longer facing sealing ring), and push sealing ring -2- onto the end of mounting cone no. 5 -1-.
Assembly sleeve turned around
6. Place mounting cone no. 5 with sealing ring onto the fuel injector from the front -1-. Using assembly sleeve no. 6 -2- , push sealing ring further onto the fuel injector.
Fitting Teflon sealing ring
The sealing ring is not yet seated in its groove.
7. Remove assembly sleeve no. 6 and mounting cone no. 5. Push sealing ring into the ring groove using assembly sleeve no. 6. => Pushing Teflon sealing ring into ring groove
Pushing Teflon sealing ring into ring groove
Calibration (shaping) of Teflon sealing ring:
7.1. Press calibrating sleeve no. 8 -1- as far as it will go over the sealing ring. Leave calibrating sleeve no. 8 => Time: 1 minute on the sealing ring.
Calibrating Teflon sealing ring
7.2. Pull off calibrating sleeve no. 8 again.
The Teflon sealing ring now has the correct installation dimension.
8. The injector should now be installed immediately, as the Teflon sealing ring will soon start to swell (prevents leaks when installed). Otherwise leave calibrating sleeve no. 8 -1- on the Teflon sealing ring for longer or fit calibration cap (transport sleeve for new injectors) -2-.
Installing high-pressure fuel injector
NOTICE
Incorrect handling of injectors
- Leaks in combustion chamber
-> Teflon sealing rings must always be replaced after removal and before refitting injectors.
-> Do not replace Teflon sealing rings until just before fitting the injector.
-> Install injector immediately after replacing the Teflon sealing ring.
Information
The tool numbers refer to the individual parts of the tools in the repair kit T10133 and the supplement set T10133/11-15 (unless indicated otherwise).
Information
- When replacing injectors, always follow the instructions on mileage and bank-specific replacement. => 244055 Replacing DFI high-pressure fuel injector - IMPORTANT.
Information
- The new fuel injectors are supplied with two transport caps fitted.
- Simply screw off the screw-on cap at the top just before fitting (screw-on cap prevents dirt from getting into the injector).
- Simply pull off the transport cap at the bottom (protective sleeve, calibrating sleeve) immediately before fitting (transport cap prevents the Teflon sealing ring from swelling).
Used injector (old) and new injector with transport protection
1. Clean bores for fuel injectors in the cylinder head thoroughly using nylon brush no. 4. Coat brush with acetone or solvent naphtha.
2. Replace damper ring (damping ring for retainer) -1- and Teflon sealing ring -arrow, Teflon sealing ring-. Replace Teflon sealing ring => 244019 Removing and installing high-pressure fuel injector (DFI) - section on "Information". Grease damper ring (damping ring for retainer) with Kluber Syntheso GLEP 1.
Damper ring
Installation position of Teflon sealing ring: -arrow-
Teflon sealing ring
3. Immediately install injector into the cylinder head at the correct installation position according to the retainer (stopping to try it out). The retainer can only be fitted onto the cylinder head in one direction (avoids confusion) -arrows-. The sides of the twist lock on the injector must be opposite the retainer and must be in as far as they will go -arrows-. Alternatively, the fuel injectors can be inserted into the retainers in pairs and can be pressed into the cylinder head two at a time when installing several fuel injectors. -arrows-
Injector twist lock in retainer
Installation lock for cylinder head retainer
3.1. To do this, insert the grease- and oil-free injector into the clean cylinder bore. Pre-set cable plug alignment.
3.2. Grease the damping rings using Kluber Syntheso GLEP 1 and press retainer onto the injectors.
3.3. Screw on retainer (the spring assembly cannot be replaced separately and may only be replaced in its entirety if the retainer is damaged irreparably). => Retainer for injectors => Tightening torque: 23 Nm (17 ftlb.)
Retainer for injectors
Subsequent work
1. Connect cable plugs for injectors.
2. Blow residual fuel out of the high-pressure system before starting the leak test. => 243001 Checking fuel distribution pipe (fuel rail) on DFI engines for leaks
3. Fit high-pressure distribution pipe (fuel rail). => 243019 Removing and installing fuel distribution pipe (fuel rail) on DFI engines - section on "Installing"
4. Perform a leak test on the high-pressure system. => 243001 Checking fuel distribution pipe (fuel rail) on DFI engines for leaks
5. Fit intake-air distributor (intake module). => 244619 Removing and installing DFI intake-air distributor - section on "Installing"
6. Connect the battery.
7. Perform a test drive. Make sure the high-pressure pipes and threaded joints are sealed properly (visual inspection with engine running).
8. Read out engine control unit fault memory after completing the work and print log. Compare with the previous log.