Fuel injectors, removing and installing

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Special tools, testers and auxiliary items required

Fig 1: Identifying Tool Set T10133

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Tool set T10133

Fig 2: High-Pressure Fuel Injector - Component Overview

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High-pressure fuel injector - component overview

Radial adjustment - Replace if damaged
Combustion chamber seal (Teflon seal) - replace, the seal must not be greased or be handled with any other lubricant during installation
Groove on fuel injector
Spacer ring - Replace if damaged
O-ring - replace, lightly coat with clean engine oil during installation
Support ring - fuel rail wields force via support ring to hold fuel injector tightly in cylinder head

Removing

CAUTION:

Fuel system is under high pressure! Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure → Procedure that must be performed before opening the high-pressure fuel injection system. Pay close attention! .
Then wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

Remove upper part of intake manifold → Intake manifold upper-part, removing and installing .
Remove corresponding intake manifold lower-part → Intake manifold lower-part with fuel rail, removing and installing .

If fuel injectors cannot be pulled out of cylinder head by hand, proceed as follows:

Fig 3: Using Screwdriver To Bend Retaining Tabs Of Radial Adjustment Aside And Pull Support Ring From Fuel Injector

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Using a screwdriver, bend retaining tabs - 1 - of radial adjustment aside - arrow - and pull support ring - 2 - from fuel injector.

Fig 4: Guiding Puller T10133/2 Into Groove On Fuel Injector And Carefully Drive Fuel Injector Out

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Attach slide wrench T10133/3 with adapter T10133/2.
Guide puller T10133/2 into groove on fuel injector and carefully drive fuel injector out.

NOTE:

When setting the puller in place, the radial adjustment can be destroyed, because the retaining tabs break.

Fig 5: Cleaning Fuel Injector In Area Of Sealing Ring

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Carefully remove old combustion chamber seal - arrow - , thereby cutting seal open with a knife or spreading seal open with a small screwdriver and pulling it forward and off.
Make sure that the groove of the fuel injector does not become damaged. If groove is damage, the fuel injector must be replaced.

Installing

NOTE:

Replace combustion chamber seal and O-ring.
Replace spacer ring if damaged.
Lightly moisten fuel injector O-rings with clean engine oil.
Re-insert injector lines at same cylinder.

Fig 6: Cleaning Bore In Cylinder Head With Nylon Cylinder Brush T10133/4

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Clean bore in cylinder head with nylon cylinder brush T10133/4.

Fig 7: Installing Fuel Injector Again With Support Ring And Clipping In Radial Compensation On Support Ring

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Clip radial adjustment - 1 - to support ring - 2 -.
When re-installing a fuel injector, use a clean cloth to clean combustion residue from groove for combustion chamber seal and shaft of fuel injector.

Fig 8: Placing Assembly Cone T10133/5 With New Teflon Seal Onto Fuel Injector

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Place assembly cone T10133/5 with new combustion chamber seal - 1 - on fuel injector - 2 -.

Fig 9: Sliding Combustion Chamber Seal As Far Possible Onto Assembly Cone T10133/5 Using Assembly Sleeve T10133/6

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Slide combustion chamber seal as far possible onto assembly cone T10133/5 using assembly sleeve T10133/6.
Turn assembly sleeve T10133/6 around and slide combustion chamber seal into groove.

NOTE:

When pushing the combustion chamber seal onto fuel injector, the seal spreads open. Therefore after pushing it on, it must be tightened again in 2 steps, as follows.

Fig 10: Pressing Calibrating Sleeve T10133/7 On To Fuel Injector Until It Stops

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Press sizing sleeve T10133/7 with a slight turning motion (approx. 180°) onto fuel injector until it stops.
Pull sizing sleeve T10133/7 off again, turning it in opposite direction.

Fig 11: Pressing Calibrating Sleeve T10133/8 On To Fuel Injector Until It Stops

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Press sizing sleeve T10133/8 with a slight turning motion (approx. 180°) onto fuel injector until it stops.
Pull sizing sleeve T10133/8 off again, turning it in opposite direction.
Moisten new O-ring 3 with clean engine oil before installing.

NOTE:

The combustion chamber seal must not be oiled.

Fig 12: Sliding Fuel Injector Into Bore Cylinder Head As Far As Stop Using Assembly Drift T10133/9

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Slide fuel injector into bore cylinder head as far as stop using assembly drift T10133/9.

NOTE:

The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.

Make sure fuel injectors are correctly positioned in cylinder head.

The electrical connection of fuel injector must engage in intended recess of cylinder head.

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

Install intake manifold lower-part → Intake manifold lower-part with fuel rail, removing and installing .
Install intake manifold upper-part → Intake manifold upper-part, removing and installing .