Fuel Injectors

Fuel Injectors

Special tools, testers and auxiliary items required

• Tool Set (T10133)

• The puller (T10133/2) was changed. It is now called puller (T10133/2A). If the new tool is not available, the old one can be modified.

Modifying the Puller (T10133/2) to (T10133/2A)

Procedure

- File a semi-circle using a round file (approximately 6 mm) as shown in the illustration.






• The semi-circle allows the puller to slide farther on to the fuel injector , thus providing the puller with a larger contact surface.

- Mark the modified puller with an "A" at the end of the tool number.

Fuel Injector (Old Version)





1 Combustion chamber seal (Teflon seal), replace When installing, the seal must not be greased or handled with any other lubricants.
2 An intermediate ring, replaces the support ring, refer to fuel injector (new version).
3 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).

Fuel Injector (New Version)





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

Removing

- Remove the intake manifold with the fuel rail. Refer to => [ Intake Manifold with Fuel Rail ] Intake Manifold with Fuel Rail.

- Cover the intake passages with a clean cloth.

• If the fuel injectors remain stuck in the fuel rail, carefully pull them out.

- Remove the support elements - A - downward and disconnect the fuel injector connectors - arrows -.






- Position the puller (T10133/2A) in the groove on the fuel injector.






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

• Pay attention to the intermediate rings.

• If new fuel injectors are not going to be installed, then clean the old fuel injectors before installing. Refer to => [ Fuel Injectors, Cleaning ] Procedures.

• The combustion chamber seal (Teflon seal) must always be replaced before reinstalling the fuel injector. Refer to => [ Fuel Injector Seal ] Fuel Injector Seal.

Installing

• The combustion chamber seal (Teflon seal) for the fuel injector must not be oiled or greased.

• It is possible an open intake valve may hinder the cleaning of the bores in the cylinder head. In this case, the engine must be rotated further by hand using a wrench on the vibration damper.

- Thoroughly clean the fuel injector cylinder head bores using a nylon brush (T10133/4).






- Replace the fuel injector combustion chamber seals (Teflon seals). Refer to => [ Fuel Injector Seal ] Fuel Injector Seal.

- Assemble the fuel injector with the parts from the repair kit.

- Press the fuel injector by hand into the cylinder head (free of oil and grease) until seated. Make sure the fuel injectors are positioned - arrow - correctly inside the cylinder head.






• If it is difficult to install the fuel injector by hand use the puller (T10133/2A) - 2 - with the hammer (T10133/3).






- Install the support ring onto the fuel injector.

- Lightly coat the O-rings for the fuel injector with clean engine oil before installing

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