TEFLON Combustion Chamber Seal
The combustion chamber seal must always be replaced before re-installing the high-pressure 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, 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. Coat 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 the high-pressure fuel injector bores 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 wrench on the crankshaft.
-- Install fuel injector again with support ring -1- and clip in radial compensation -2- on support ring.
The Teflon sealing ring of fuel injector may not be oiled or greased.
When installing the injector valve, make sure there is no cleaning product or oil in the holes in the cylinder head.
-- Using the 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 performed in reverse order.
Important: The following points must always be observed:
The Teflon sealing ring of fuel injector may not be oiled or greased.
When installing the injector valve, make sure there is no cleaning product or oil in the holes in the cylinder head.
Coat high pressure fuel injector O-rings with clean engine oil so they are easier to guide into the fuel rail.
Replace all seals.
The fuel rail should be placed on the fuel injectors and pressed on evenly.
Install intake manifold with fuel rail. Refer to INTAKE MANIFOLD WITH FUEL RAIL