Fuel Injector: Service and Repair
Fuel Injectors
Special tools, testers and auxiliary items required
• Tool Set (T10133)
• Puller (T10133/2A)
• Hammer (T10133/3)
• Nylon Cylinder Brush (T10133/4)
• Assembly Cone (T10133/5)
• Assembly Sleeve (T10133/6)
• Sizing Sleeve (T10133/7)
• Sizing Sleeve (T10133/8)
• Removal Tool (T10133/16)
Removing
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 => [ Releasing Pressure in High Pressure Area ] Releasing Pressure In High Pressure Area.
- Reduce the 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 intake manifold lower section. Refer to => [ Intake Manifold Lower Section, with Fuel Rail ] Intake Manifold Lower Section, With Fuel Rail.
- Position the (T10133/2A) in the groove on the fuel injector.
- Then position the (T10133/16) and remove the fuel injector by loosening the bolt - 1 -.
Disassemble the Fuel Injector
- Remove the support ring - 4 -, O-ring - 3 - and spacer ring - 2 - from the fuel injector - 1 -.
- Remove the circlip - 7 - and upper sealing washer - 5 - and lower sealing washer - 6 -.
- Carefully remove the old combustion chamber seal - 8 - 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 combustion chamber seal and O-ring.
• Replace spacer ring if damaged.
• Lightly coat the fuel injector O-rings with clean engine oil.
• Install the cylinder at the same cylinder.
- Clean the bore in cylinder head with (T10133/4).
- Place the (T10133/5) with a new combustion chamber seal - 1 - from the repair set onto the fuel injector - 2 -.
- Slide the combustion chamber seal as far possible onto the (T10133/5) using (T10133/6).
- Turn the (T10133/6) around and slide the 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 (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 (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.
- Install the parts form the repair set on the injector valve - 1 -:
2 Spacer ring
3 O-ring
4 Support ring
5 Upper sealing washer - note installation position
6 Lower sealing washer - note installation position
7 Circlip - do not overstretch
- Coat the new O-ring with clean engine oil before installing.
• The combustion chamber seal - 8 - 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 the fuel injectors are positioned correctly in cylinder head.
• The fuel injector must not be difficult to install. If necessary, wait as the seal continues to pull itself together.
• Check the fuel injectors for correct seating and installation position in cylinder head.
• If it is difficult to install the fuel injector by hand use the (T10133/2A) - 2 - with the (T10133/3).
• The electrical connection of the fuel injector must engage in the intended recess of the cylinder head.
• Coat the high pressure fuel injector O-rings with clean engine oil so they are easier to guide into the fuel rail.
• Replace all seals.
Further installation is performed in reverse order of removal, noting the following:
- Install the lower intake manifold section. Refer to => [ Intake Manifold Lower Section, with Fuel Rail ] Intake Manifold Lower Section, With Fuel Rail.
- Install the supercharger.