Removing High-Pressure Fuel Injector

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Toxic substances

Danger of poisoning or suffocation
Danger of burns to the eyes and skin

→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Wear personal protective gear.

→ Do not smoke, eat or drink in the work area.

WARNING: Highly inflammable or explosive materials

Danger of fire or explosion

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapours.

→ Attach warning sign in a clearly visible position.

NOTE: Dirt on injection system components

Material damage
Rough-running engine
Bad exhaust emissions

→ Thoroughly clean connection points and adjacent areas before loosening them. If the engine is very dirty, wash it before starting disassembly work.

→ Lay removed parts on a clean surface and cover them. Do not use fibre-shedding cloths.

→ Carefully cover components or seal them if repair work will not be carried out immediately. Place rubber caps on connections. Seal intake openings with film or adhesive tape.

→ Only install clean parts. Do not take spare parts out of the packaging until just before installation.

→ Never use compressed air when the system is open. Do not move the vehicle.

WARNING: Leaking fuel supply lines

Emerging fuel
Risk of fire

→ Perform leak test.

Information

Do not bend high-pressure lines. Always remove the high-pressure distributor pipe and other fuel-supply components in the high-pressure area completely. Check that the connection points are not damaged and are perfectly clean and make sure there is no thread damage. Fit union nuts on all connection points by hand before screwing in screws or bolts. Remove dirt on the conical/ball joints. Check connection points for leaks following fitting.

Information

Absorb any escaping fuel using a suitable binding material or a cloth.
Cloths which have absorbed fuel must be disposed of according to the applicable national laws.
The fuel system must be depressurised before starting work on it.
Only work on the fuel system in well-ventilated rooms.
Any seals which have been removed must always be replaced.
Do not use any sealant containing silicone or silicone spray when the injection system is open. Traces of silicone drawn in by the engine are not combusted and damage the oxygen sensors.

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).

Pull injector out of the cylinder head by hand (using a glove!). Turn injector slightly if necessary.
If the injector is stuck in the cylinder head due to coking of the injector tips, proceed as follows:
Pull upper O-ring on the injector upwards by hand as shown and remove it. Use a small screwdriver to help, if necessary.

Fig 1: Removing Fuel Injector Sealing Rings
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Bolt impact hammer no. 3 to puller no. 15 -1- .

Fig 2: Identifying Fuel Injector Impact Hammer
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Fit impact hammer with puller no. 15 into the groove -arrow- on the fuel injector.

Fig 3: Locating Groove On Fuel Injector
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Tap gently on the fuel injector to remove it. Use impact hammer -1- and puller -2- as shown.

Fig 4: Pulling Out Fuel Injector USing Tool
Courtesy of PORSCHE CARS NORTH AMERICA, INC.