Fuel Injectors
Fuel Injectors
Special tools, testers and auxiliary items required
• Tool Set (T10133)
• The puller (T10133/2) has been changed. It is now called the puller (T10133/2 A). If the new tool is not available, the old one can be modified.
Convert the puller (T10133/2) to the puller (T10133/2 A).
Special tools, testers and auxiliary items required
• Round file approximately 6 mm
- File the semicircle as shown in the illustration. The semi-circle allows the tool to slide farther onto the fuel injector, thus providing the tool with a larger contact surface.
- Mark the modified tool with an A at the end of the tool number.
Removing
- Install the protective body covers. Refer to => [ Protective Body Covers, Installing ] Procedures.
- Remove the 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 - arrow -, bend the retaining tabs - 1 - of the radial adjustment aside and pull the support ring - 2 - from the fuel injector.
- Position the (T10133/2A) in the groove on the fuel injector.
- Position the removal tool (T10133/16) on the puller. Pull the bolt - 1 - in to remove the fuel injector.
- Remove the O-ring - 5 - and spacer ring - 4 - from the fuel injector - 3 -.
- Carefully remove the old combustion chamber seal - 2 - by cutting the sealing ring with a knife and prying it open with a small screwdriver.
- 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.
- Clean bore in cylinder head with nylon cylinder brush (T10133/4).
- Clip the radial adjustment - 2 - to the support ring - 1 -.
- 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 (T10133/5) using assembly sleeve (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 sizing sleeve (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 sizing sleeve (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.
- Install the parts form the repair kit on the injector valve - 3 -:
1 Radial adjustment
4 Spacer ring
5 O-ring
6 Support ring
- Coat the new O-ring with clean engine oil before installing.
• Do not oil or grease the fuel injector combustion chamber seal - 2 -.
• When installing the injector valve, make sure there is no cleaning product or oil in the holes in the cylinder head.
- Press the fuel injector by hand into the bore in the cylinder head (free of oil and grease) until it stops. Make sure fuel injectors are positioned correctly in cylinder head.
• The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.
• Check fuel injectors for correct seating and installation position in cylinder head.
• If it is difficult to install the fuel injector by hand use the (T10133/2A) - 2 - with the slide hammer (T10133/3).
- Further installation is performed in reverse order.
The Following Points Must Always be Observed:
• Coat the O-rings for the high pressure fuel injectors with clean engine oil so they are easier to guide into the fuel rail.
• Replace all seals.
• The fuel rail should be placed on the fuel injectors and pressed on evenly.
• Install the lower intake manifold section. Refer to => [ Intake Manifold, Lower Section, with Fuel Rail ] Intake Manifold, Lower Section, With Fuel Rail.