Fuel Injector: Service and Repair

Fuel Injectors

Special tools, testers and auxiliary items required

• Tool Set (T10133)

Removing

Danger of personal injury from the high fuel pressure!

• Reduce the fuel pressure down to a residual pressure before opening the high pressure side of the fuel injection system.

• To reduce the remaining residual pressure, lay a clean cloth around the connector and carefully open the connector.

- Release the high side fuel pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

- Remove the supercharger. Refer to => [ Supercharger ] Supercharger.

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

- Install the puller (T10133/2A) into the groove in the fuel injector.






- Install the removal tool (T10133/16) on the puller, turn the bolt - 1 - and remove the fuel injector.

Disassembling the Fuel Injector:






- Remove the support ring - 4 -, O-ring - 3 - and spacer ring - 2 - from the fuel injector - 1 -.

- Remove the seal - 5 -.

- Carefully remove the old combustion chamber seal - 6 - by cutting the seal with a knife and prying it open with a small screwdriver.

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

Installing

• Replace the combustion chamber seal and O-ring.

• Replace the spacer ring if damaged.

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

• Install the injector to the same cylinder.

- Clean the hole in the cylinder head using the nylon cylinder brush (T10133/4).






- Place the assembly cone (T10133/5) with new combustion chamber seal - 1 - onto the fuel injector - 2 -.






- Slide the combustion chamber seal with the assembly sleeve (T10133/6) as far as possible onto the assembly cone (T10133/5).






- Turn the guide sleeve (T10133/6) and the combustion chamber seal until the they slide into the 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.






- Turn the sizing sleeve (T10133/7) in the opposite direction and remove it.

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






- Turn the calibration sleeve (T10133/8) in the opposite direction and remove it.

- Install the components from the repair kit onto the fuel injector - 1 -:






2 Spacer, the collar faces the fuel injector
3 O-ring
4 Support ring
5 Washer

- Lightly lubricate the new O-ring with clean engine oil before installing

• The combustion chamber seal - 8 - must not be lubricated.

- Slide the fuel injector into the cylinder head bore as far as stop 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 the fuel injector is positioned correctly in the cylinder head:

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

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

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

- Install the supercharger. Refer to => [ Supercharger ] Supercharger.