Removing Fuel Collection Pipe With Fuel Injectors

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

1. Observe safety instructions when working on the fuel system.

   → 2001AW BASIC SAFETY INSTRUCTIONS FOR WORKING WITH THE FUEL SYSTEM .

2. Detach high-pressure connecting line between the fuel collection pipes.
   1. 2.1. Cover intake ports on the cylinder head and place a clean, lint-free cloth under the fuel collection pipe and high-pressure connecting line -3-  .

      Collect emerging fuel with the cloths.

   2. 2.2. Unscrew union nuts -1-  using open-ended wrench (a/f 17) -2-  .
      Fig 1: Removing Fuel High-Pressure Line Threaded Connections On Side 1-3

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   3. 2.3. Unscrew union nut -1-  using open-ended wrench (a/f 17) -2-  .
      Fig 2: Removing Fuel High-Pressure Line Threaded Connection On Side 4-6

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   4. 2.4. Loosen clamps -1-  for connecting line. Unscrew and remove external Torx screws: M6 x 12 in the center, M6 x 16 on the right.
      Fig 3: Locating Connecting Line Clamps

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Remove fuel collection pipe (side 1-3 or 4-6).
   1. 3.1. Unscrew and remove four external Torx screws (M6 x 30) -1-  used to secure the fuel collection pipe -2-  .
      Fig 4: Identifying Screws On Fuel Collection Pipe

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Information 

   • When removing and installing the fuel injectors, the following components must always be replaced to guarantee function and leaktightness. 
   • O-ring, spring clamp, bellows and Teflon sealing ring. 
4. Pull off spring clamps -1-  on the fuel injectors using a pair of small flat-nosed pliers if possible.
   1. 4.1. If this is not possible because they are inaccessible, pull out fuel collection pipe with the fuel injectors.
   2. 4.2. If this is not possible because the fuel injectors are stuck (metal corrosion between stainless steel and aluminum), spray valve seats with anti-rust agent (e.g. WD 40 or Caramba) and leave it to take effect.

      Remove excess anti-rust agent with a cloth.

   3. 4.3. Carefully move the fuel collection pipe back and forth. Then push a plastic or wooden wedge (shop made) under the pipe and lift it.
   4. 4.4. Disconnect cable plugs for fuel injectors and lift the module with the valves out of the engine compartment.
   5. 4.5. Remove spring clamps, pull fuel injectors out of the pipe adapter as vertically as possible (axially).
   6. 4.6. Always replace the spring clamps.
      Fig 5: Locating Fuel Injector Spring Clamp

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. Fuel injectors -1-  can remain in the cylinder head, depending on the age of the vehicle and driving performance.
   CAUTION: Spring clamps can become loose and fall into the engine compartment when the fuel collection pipe is pulled off.
   1. 5.1. Remove them immediately.
      Fig 6: Identifying Fuel Injectors In Cylinder Head

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. Pull fuel injector out of its seat in the cylinder head. Use special tool Repair Kit T10133  with Puller Arms For T10133/1 - Kit T10133/30  to do this.
   1. 6.1. Free fuel injector using a twisting motion.
   2. 6.2. Puller Arms For T10133/1 - Set T10133/30  must be positioned on the fuel injector -2-  . Insert the lever arms into the cut-outs on the injector -arrow-  and lock them by screwing the hexagon nut -1-  clockwise.
      Fig 7: Locating Puller Arms On Fuel Injector

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   3. 6.3. Screw slide hammer from the repair kit onto the hexagon nut -1-  . Press lever arms -2-  together and remove the injector by pulling up gently.
      Fig 8: Pulling Fuel Injector (Side 1-3)

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Side 4-6:

      1. Slide hammer with pull rod
      2. Fuel injector
      3. Intake port cover (adhesive tape) - remove adhesive residue
         Fig 9: Pulling Fuel Injector (Side 4-6)

         Courtesy of PORSCHE CARS NORTH AMERICA, INC.
   4. 6.4. Tool on injector
      1. Slide hammer with pull rod
      2. Hexagon nut for locking lever arms

         arrow  - Position of retaining bore for pulling lever arms

      3. Fuel injector (high-pressure injector)
         Fig 10: Locating Special Tool On Injector

         Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. Carefully clean fitting bores on cylinder head.
   1. 7.1. Remove loose parts using a powerful workshop vacuum cleaner.
   2. 7.2. Soak a small, clean and lint-free cloth in acetone or solvent naphtha and carefully clean the bores.
   3. 7.3. Use the cleaning brush from the tool set to remove any remaining dirt from the fitting bores.
8. Clean fuel collection pipe.
   1. 8.1. Clean connection piece for the fuel injectors with acetone or solvent naphtha.
9. Fuel injectors that are to be re-installed must also be cleaned (see CLEANING FUEL INJECTORS ).

   Information 

   • When the work is complete, check that all aids and foreign objects (e.g. cloths, tools) are removed from the engine compartment. 
10. Make sure there are no tools, foreign objects or aids in the engine compartment.