Installing Injector Valve

Information 

• The removal and installation of the injector valves is described using tools from the  > T10133C - tool kit  :
• Puller T10133/2A 
• Impact hammer T10133/3 
• Assembly cone T10133/5 
• Assembly sleeve T10133/6 
• Calibrating sleeve T10133/7+8 
• Calibration sleeve  > T90011 - tool kit (HDEV5) 
• Assembly pin T10133/9 
• Sleeve T10133/18A 
• Puller  > T10498 - Disassembly Tool 
• M8 screw T10133/21 
• Brush  > T90006 - Cleaning Tool 
• Teflon sealing ring 

Information 

The fuel injector groove must not be damaged.

1. If you intend to re-use the old injector valve:  Replace the Teflon sealing ring -1-  .
   1. 1.1  Position injector valve up to -3-  of > VAS 211 015 - disassembly tool  .
   2. 1.2  Removing of Teflon sealing ring -1-  using > VAS 211 015 - disassembly tool-2- 

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      Using disassembly tool VAS 211 015

   3. 1.3  Clean the groove on the Teflon sealing ring -1-  and the injector valve stem with a clean cloth and acetone or solvent naphtha to remove combustion residues.
2. Fit assembly cone -1-  with a new  Teflon sealing ring onto injector valve -3-  .

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   Assembly cone

3. Using assembly sleeve -1-  , push the Teflon sealing ring as far as possible onto the mounting cone -2-  and turn the assembly sleeve -1-  until the Teflon sealing ring is pushed into the groove on the injector valve -3-  .

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   Teflon sealing ring

4. Calibrate Teflon sealing ring on injector valve -1-  .

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   Calibrating sleeve

   1. 4.1  Press the calibration sleeve -2-  as far as the anchor block onto injector valve -1-  by turning it slightly (by about 180°).
   2. 4.2  Pull the calibration sleeve -2-  off again by turning it in the opposite direction.
   3. 4.3  Repeat the process using a second calibrating sleeve from the tool set.
5. Replace other parts on the injector valve -1-  . 1) 

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   Injector valve

   Information 

   The O-ring must be coated with engine oil.

   The Teflon sealing ring must not be oiled.

   1. 5.1  Replace O-ring -3-  , support washer -4-  and intermediate ring -5-  .
   2. 5.2  Check supporting plate -2-  for damage and only replace it if necessary.
      1. The Teflon sealing ring, O-ring and support washer are available as a repair kit in the Parts Information.

   Information 

   The fuel injector must fit in easily.

   If this is not the case, wait until the Teflon sealing ring has contracted.

6. Insert the injector valve -1-  as far as the anchor block into the bore in the cylinder head using assembly driver -2-  .

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   Assembly driver on injector valve