Fuel Injector: Service and Repair

Fuel Injectors

Special tools, testers and auxiliary items required

• Tool Set (T10133)

Removing

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

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

- Reduce fuel pressure in high pressure area. Refer to => [ Releasing Pressure in High Pressure Area ] Releasing Pressure In High Pressure Area.

- Remove the supercharger.






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

- Mount the puller (T10133/2A) into the groove on the fuel injector.






- Mount the removal tool (T10133/16) and turn to the bolt - 1 - to remove the fuel injector.

Disassemble 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 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 the sealing washer, the combustion chamber seal and the O-ring.

• Replace the sealing ring if it is damaged.

• Lubricate the fuel injector O-rings lightly with clean engine oil.

- Clean the hole inside the cylinder head with a nylon cylinder brush (T10133/4).

- When 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 the assembly cone (T10133/5) with a new combustion chamber seal - 1 - from the repair set onto the fuel injector - 2 -.






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






- Turn the (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 calibration sleeve (T10133/7) with a gentle turning movement (approximately 180°) all the way onto the fuel injector.

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

- Press the calibration sleeve (T10133/8) with a gentle turning movement (approximately 180°) all the way onto the fuel injector.






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

- Install the components from the repair set on the fuel injector - 1 -:






2 Spacer ring
3 O-ring
4 Support Ring
5 Washer

- Coat the new O-ring with oil before installing it. This makes it easier to install the fuel injector in the fuel rail.

• The combustion chamber seal - 6 - 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 the 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 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.

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

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

- Install the supercharger.