Teflon Combustion Chamber Seal, Replacing

Teflon Combustion Chamber Seal, Replacing

• The combustion chamber seal must always be replaced before re-installing the fuel injector.

- The illustration shows the fuel injector.





1 Radial compensation, replace if damaged
2 Combustion chamber sealing ring (Teflon sealing ring), replace, the ring must not be greased or handled with any other lubricants when installing.
3 Groove on fuel injector
4 Spacer ring, replace if damaged
5 O-ring (replace, coat lightly with clean engine oil when installing)
6 Support ring (via this support ring, the fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

- Carefully remove the old Teflon seal with the appropriate tool (e.g. 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.

• A fuel injector with "angled connector" is shown in the illustration. Do not pay attention to this for the remainder of the procedure, because it is unrelated to replacement of the combustion chamber seal.

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





- Using the assembly sleeve (T10133/6), push the Teflon seal further onto the assembly cone (T10133/5) until the Teflon seal is engaged in the seal groove. When doing this, do not use any lubricants.





• By pushing the Teflon seal onto the fuel injector, the Teflon seal is expanded. For this reason, the Teflon seal must be contracted again, once it has been pushed on. This is done in two steps. The procedure for this is as follows.

The 1st step of calibrating (adapting) the Teflon seal is performed using the calibration sleeve (T10133/7).

- Using a rotating motion (approximately 180) and light pressure, push the calibration sleeve (T10133/7) over the fuel injector up to the stop. Pull the calibration sleeve (T10133/7) off again, rotating it in the opposite direction.





The 2nd step of calibrating (adapting) the Teflon seal is performed using the calibration sleeve (T10133/8).

- Using a rotating motion (approximately 180) and light pressure, push the calibration sleeve (T10133/8) over the fuel injector up to the stop. Pull the calibration sleeve (T10133/8) off again, rotating it in the opposite direction.





- Replace O-ring on fuel injector. Moisten the O-ring with clean engine oil before installing.

- The Teflon seal must not be oiled.

- Using the included nylon brush (T10133/4), thoroughly clean bores for the high-pressure fuel injectors in the cylinder head before installing the fuel injectors.





• Possibly an opened intake valve hinders the cleaning. In this case, engine must be turned further by hand using a screw wrench on the crankshaft.

- Install fuel injector again with support ring - 1 - and clip in radial compensation - 2 - on support ring.





- Using assembly drift (T10133/9), press the fuel injector into the intended bore in the cylinder head until it stops. Make sure fuel injectors are positioned correctly in cylinder head.





- Further installation is in reverse order of removal.

- Install intake manifold with fuel rail. Refer to => [ Fuel Rail ] Fuel Rail