Fuel Injectors

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Tool Set T10133

NOTE:

Puller T10133/2 was changed and is now called 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 and workshop equipment required

Round file approximately 6 mm

-- File the semicircle as shown in the illustration. The semicircle 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.

Fig 1: File Semi-Circle

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High Pressure Fuel Injector, Assembly Overview

Fig 2: High-Pressure Fuel Injector - Component Overview

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Radial adjustment - Replace if damaged
Combustion chamber seal (Teflon seal) - replace, the seal must not be greased or be handled with any other lubricant during installation
Groove on fuel injector
Spacer ring - Replace if damaged
O-ring - replace, lightly coat with clean engine oil during installation
Support ring - fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head

Removing

WARNING:

There is a risk of injury because the fuel is under very high pressure.

The fuel pressure must be reduced to residual pressure before opening the high pressure area of the fuel injection system. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .
To reduce remaining residual pressure, lay a clean cloth around the connector and carefully loosen connector.

-- Remove the upper section of the intake manifold. Refer to INTAKE MANIFOLD, UPPER SECTION .

-- Remove the affected intake manifold lower section. Refer to LOWER INTAKE MANIFOLD 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.

Fig 3: Identifying Screwdriver, Retaining Tabs Of Radial Adjustment And Support Ring From Fuel Injector

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

Fig 4: Identifying Position Of Puller T10133/2A In Groove On Fuel Injector & Trim Removal Wedge T10133/16

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

NOTE:

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.

Fig 5: Cleaning Fuel Injector In Area Of Sealing Ring

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-- 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

NOTE:

Replace the combustion chamber seals and O-rings.

Replace the spacer ring and radial adjuster if damaged.

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

Install the cylinder at same cylinder.

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

Fig 6: Identifying Radial Adjustment & Support Ring

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-- 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-.

Fig 7: Identifying Assembly Cone T10133/5, New Teflon Seal And Fuel Injector

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-- Slide combustion chamber seal as far possible onto assembly cone T10133/5 using assembly sleeve T10133/6.

Fig 8: Identifying Combustion Chamber Seal Inserted On Assembly Cone T10133/5 Using Assembly Sleeve T10133/6

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

NOTE:

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.

Fig 9: Identifying Calibrating Sleeve T10133/7 Pressed On To Fuel Injector Until It Stops

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-- 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.

Fig 10: Identifying Calibrating Sleeve T10133/8 Pressed On To Fuel Injector Until It Stops

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

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

NOTE:

The combustion chamber seal must not be oiled.

Fuel Injectors, Installing

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

Fig 11: Cleaning Bore In Cylinder Head With Nylon Cylinder Brush T10133/4

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-- 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.

NOTE:

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 puller T10133/2A -2- with the hammer T10133/3.

Fig 12: Identifying Installation Hammer T10133/3 To Puller T10133/2

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

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

-- Install the lower section of the intake manifold. Refer to LOWER INTAKE MANIFOLD WITH FUEL RAIL .

-- Install the upper section of the intake manifold. Refer to INTAKE MANIFOLD, UPPER SECTION .