Fuel Injectors

Fuel Injectors

Special tools, testers and auxiliary items required

• Tool Set (T10133)

Removing

• The following describes removing and installing and the left injectors (cylinder bank 2).

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

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

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





- Then position the removal tool (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.

• Re-insert injectors at same cylinder.

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





- 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 (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.

• The combustion chamber seal must not be oiled.

- 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 using the puller (T10133/2A) - 2 - with the hammer (T10133/3).





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

• Coat the fuel injectors O-rings with clean engine oil so they are easier to guide into the fuel rail.

• Replace all seals.

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

• Tightening specification, refer to => [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview

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

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

- Only install retaining tabs after high pressure lines have been tightened.

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

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