Replacing Teflon Sealing Ring On 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).

Installation Position Of Teflon Sealing Ring: -arrow-

Fig 1: Locating Teflon Sealing Ring

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Remove high-pressure fuel injector.
Replace large sealing ring for long fuel injectors for cylinders 1, 3 and 5.
Clean fuel injector carefully using a plastic brush (or cloth) and acetone or solvent naphtha. Hold sealing ring gently using pointed-nose pliers and carefully pull off Teflon sealing ring -1- . Do not scratch valve body.

Fig 2: Removing Teflon Sealing Ring
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Also clean sealing ring groove in the area of the sealing ring. Remove any deposits (coking).
Place new sealing ring -2- onto mounting cone no. 5 -1- .

Fig 3: Identifying Teflon Sealing Ring On Mounting Cone
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Using assembly sleeve no. 6 (knurled side facing the sealing ring) -3- push sealing ring gently as far as it will go onto mounting cone no. 5 → Teflon sealing ring on mounting cone .
Turn assembly sleeve no. 6 -3- around (knurled side now no longer facing sealing ring), and push sealing ring -2- onto the end of mounting cone no. 5 -1- .

Fig 4: Identifying Assembly Sleeve Turned Around
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Place mounting cone no. 5 -1- with sealing ring onto the fuel injector from the front. Using assembly sleeve no. 6 -2- push sealing ring further onto the fuel injector.

Fig 5: Fitting Teflon Sealing Ring
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The Teflon Sealing Ring Is Not Yet Seated In Its Groove!
Remove assembly sleeve no. 6 and mounting cone no. 5. Push sealing ring into the ring groove using assembly sleeve no. 6.
Calibration (Shaping) Of Teflon Sealing Ring:
1. 9.1. Push spacer sleeve no. 11 -1- onto the valve body.
  
  Fig 6: Identifying Spacer Sleeve
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 9.2. Press calibrating sleeve no. 7 -2- over the sealing ring until it stops against spacer sleeve no. 11.
3. 9.3. Pull off calibrating sleeve no. 7 again.
4. 9.4. Press calibrating sleeve no. 8 -4- over the sealing ring until it stops against spacer sleeve no. 11 -3- .
  
  Fig 7: Identifying Calibrating Sleeve
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 9.5. Pull off calibrating sleeve no. 8 again.
  The Teflon Sealing Ring Now Has The Correct Installation Dimension .
The injector should now be installed immediately, as the Teflon sealing ring will soon start to swell (prevents leaks when installed).