Fuel Injectors

Fuel Injectors

Special tools, testers and auxiliary items required

• Tool Set (T10133)

• The Puller (T10133/2) was changed and is now called the Puller (T10133/2-A). If the new tool is not available, the old one can be modified.

Modify the Puller (T10133/2) to create the Puller (T10133/2-A).

Special tools, testers and auxiliary items required

• Round file approximately 6 mm

- File the semi-circle as shown in the illustration. The semi-circle allows the tool to slide farther onto the fuel injector. This provides the tool with a larger contact surface.

- Mark the modified tool with an "A" at the end of the tool number.





Removing


• 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 intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

• Seal injector channels in cylinder heads with clean cloths.

- Disconnect electrical harness connectors at fuel injectors.

- Remove high pressure line - 5 - from connector on fuel rail.





- Remove high pressure line - 7 - from connector on fuel rail. To do this, counterhold at hex head with and open-end wrench and loosen the union nut.

- Remove bolts - 1, 2, 3, 4, 6, 8 -.

• Do not change the angles of the high pressure lines.

- Remove fuel rail with fuel injectors.

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.

- Remove O-ring from fuel injector.

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





- Then position the Trim Removal Wedge (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 Teflon seal - arrow - with the appropriate tool (for example with cut the seal open with a razor and spread seal open with a small screwdriver and pull it forward and off.) When doing this, make sure not to damage the groove and circumferential rib in the groove base.





• If the groove is damage, the fuel injector must be replaced.

- Before installing the new Teflon seal, the seal groove and the shaft of the fuel injector must be cleaned of combustion residue using a clean rag.

Installing

• Replace combustion chamber seal and O-ring.

• Replace spacer ring if damaged.

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

• Re-insert injector lines at same cylinder.

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





- When re-installing 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 Assembly Cone (T10133/5) with new combustion chamber seal - 1 - on fuel injector - 2 -.





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





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

• When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. This combustion chamber seal must therefore be made smaller after pushing it on in 2 steps.





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

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

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





- Pull the Sizing Sleeve (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.

• Do not put any grease, oil or other lubricants on the combustion chamber seal.

Fuel Injectors, Installing:

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





- Slide the injector valve into the hole in the cylinder housing using the Assembly Drift (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.

- Press the fuel rail onto the fuel injectors with uniform pressure.





- Tighten bolts - 1, 2, 3, 4, 6, 8 - diagonally in stages.

Further installation is in reverse order.

• For the tightening specifications. Refer to => [ Fuel Injectors with Fuel Rail Assembly Overview ] Fuel Injectors With Fuel Rail Assembly Overview.

• High pressure line connections must not show any signs of damage.

• Do not change the angles of the high pressure lines.

- Install intake manifold. Refer to => [ Intake Manifold ] Intake Manifold.

- High pressure lines, installing. Refer to => [ High Pressure Lines, Installing ] Service and Repair.