Installing High-Pressure Fuel Injector

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NOTE: Incorrect handling of injectors

Leaks in combustion chamber

→ Teflon sealing rings must always be replaced after removal and before refitting injectors.

→ Do not replace Teflon sealing rings until just before fitting the injector.

→ Install injector immediately after replacing the Teflon sealing ring.

Information

The tool numbers refer to the individual parts of the tools in the Repair Kit T10133 and the Supplement Set T10133/11-15 (unless indicated otherwise).

Clean bores for fuel injectors in the cylinder head thoroughly using the nylon brush no. 4 -arrow- . Coat brush with acetone or solvent naphtha.

Fig 1: Cleaning Bore In Cylinder Head
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Check plastic support washer for damage and replace it if necessary.
To Replace The Damaged Plastic Support Washer:
1. 2.1. Remove O-ring -3- .
  
  Fig 2: Removing O-Ring
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Cut open support washer -2- using small side cutters and remove it.
3. 2.3. Pull off spring element for fuel injector -1- and slide on tab washer no. 12 -1- instead.
4. 2.4. Push new support washer -3- on to mounting cone no. 13 -2- and fit it on the fuel injector as shown.
5. 2.5. Push the support washer -3- using calibrating sleeve no. 14 (knurled side facing the fuel injector) -4- on to the fuel injector as far as the first groove -arrow- .
  
  Fig 3: Replacing Support Washer
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
6. 2.6. Turn calibrating sleeve no. 14 -3- around (knurled side no longer facing fuel injector).
  
  Fig 4: Turning Calibrating Sleeve
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
7. 2.7. Push calibrating sleeve -3- over the support washer -2- in direction of arrow until it stops against tab washer no. 12 -1- .
8. 2.8. Remove calibrating sleeve no. 14 again. The Support Washer Now Has The Correct Installation Dimension .
Replace O-ring -3- , Teflon sealing ring and spring element for injector -1- . Fit a new spring element - and a new O-ring - in front of the support washer instead of tab washer no. 12. Replace Teflon sealing ring → INFORMATION - section on "Information".

Fig 5: Identifying Spring Element And O-Ring
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Immediately install injector into the cylinder head at the correct installation position. To do this, insert the grease- and oil-free injector into the clean cylinder bore.