Fuel Injector: Service and Repair

Fuel Injectors

Special tools, testers and auxiliary items required

• Tool Set (T10133)

High-pressure fuel injector - component overview





1. Radial adjustment - Replace if damaged

2. Combustion chamber seal (Teflon seal) - replace, the seal must not be greased or be handled with any other lubricant during installation

3. Groove on fuel injector

4. Spacer ring - Replace if damaged

5. O-ring - replace, lightly coat with clean engine oil during installation

6. Support ring - fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head

Removing

CAUTION!
• Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

• Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

- Remove upper section of intake manifold. Refer to => [ Intake Manifold Upper Section ] Intake Manifold Upper Section.

- Remove the corresponding intake manifold lower-section. Refer to => [ Intake Manifold Lower Section with Fuel Rail ] Intake Manifold Lower Section With Fuel Rail.

If the fuel injectors cannot be pulled out of the cylinder head by hand, proceed as follows:

- Using a screwdriver, bend the retaining tabs - 1 - of the radial adjustment aside - arrow - and pull the support ring - 2 - from the fuel injector.





- Position the (T10133/2A) in the groove on the fuel injector.





- Then position the (T10133/16) and remove the fuel injector by loosening the bolt - 1 -.

• When setting the puller in place, the radial adjustment can be destroyed, because the retaining tabs break.

- Carefully remove the old combustion chamber seal - arrow -, thereby cutting seal open with a knife or spreading seal open with a small screwdriver and pulling it forward and off.





- Make sure that the groove of the fuel injector does not become damaged. If the groove is damage, the fuel injector must be replaced.

Installing

• Replace combustion chamber seal and O-ring.

• Replace spacer ring if damaged.

• Lightly coat fuel injector O-rings with clean engine oil.

• Reinsert injector lines at same cylinder.

- Clean bore in cylinder head with (T10133/4).





- Clip the radial adjustment - 1 - to the support ring - 2 -.





- When reinstalling a fuel injector, use a clean cloth to clean combustion residue from the groove for combustion chamber seal and the shaft of the fuel injector.

- Place (T10133/5) with new combustion chamber seal - 1 - on fuel injector - 2 -.





- Slide combustion chamber seal as far possible onto (T10133/5 ) using (T10133/6).





- Turn (T10133/6) around and slide combustion chamber seal into groove.

• When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. Therefore after pushing it on, it must be tightened again in 2 steps, as follows.

- Press the (T10133/7) with a slight turning motion (approximately 180°) onto the fuel injector until it stops.





- Pull the (T10133/7) off again, turning it in the opposite direction.

- Press the (T10133/8) with a slight turning motion (approximately 180°) onto the fuel injector until it stops.





- Pull the (T10133/8) off again, turning it in the opposite direction.

- Coat the new O-ring with clean engine oil before installing.

• The combustion chamber seal must not be oiled.

- Slide fuel injector into the bore cylinder head as far as stop using (T10133/9).





• The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.

- Make sure fuel injectors are correctly positioned in cylinder head.

• The electrical connection of the fuel injector must engage in the intended recess of the cylinder head.

Further installation is in reverse order of removal, note the following:

- Install intake manifold lower section. Refer to => [ Intake Manifold Lower Section with Fuel Rail ] Intake Manifold Lower Section With Fuel Rail.

- Install intake manifold upper section. Refer to => [ Intake Manifold Upper Section ] Intake Manifold Upper Section.