Installing Fuel Injector

Information 

• When removing and installing the fuel collection pipe, always replace the spring clamp and O-ring on the fuel injector. 
• When removing and installing the fuel injectors, also replace the large O-ring and the Teflon ring in order to guarantee function and prevent leaks. 

Component overview: 

Fig 1: Fuel Injector Components Location

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1. Fuel injector - follow cleaning instructions!
2. O-ring - replace and coat with new engine oil 
3. Support ring - replace if necessary
4. Spring clamp - replace 
5. Sealing ring - replace 
6. Spacer ring - replace if necessary
7. Stainless steel circlip - replace if necessary
8. Teflon sealing ring - replace 

1. Grip Teflon sealing ring -1  - carefully using pointed-nose pliers -2  - and pull it off. Do not scratch the valve body.
   1. 1.1 Scratched valves must be replaced.

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2. The fuel injectors must be cleaned during re-installation.

   NOTIFICATION 

   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.

   Cleaning if lightly soiled: 

3. Clean valve tips using a soft, lint-free cloth with acetone or solvent naphtha.
   1. 3.1 Also clean sealing ring groove.

   Cleaning if heavily soiled: 

4. Clean valve tips in an ultrasound bath. This allows even stubborn deposits (coking) to be removed.
   1. 4.1 Plunge just the metal insert into the cleaning fluid, holding it as vertically as possible. Cover electric connection with adhesive tape.
5. Replace small and large O-ring and coat with new engine oil.
6. Position new Teflon sealing ring -2  - on the > T10133/31 - mounting cone-1  -.
   1. 6.1 Push sealing ring onto the cylinder of the mounting cone by hand and move it to the very end -item 3-  .

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7. Slide sealing ring -2  - over the mounting cone -1  - onto the fuel injector nozzle tip -3  -.
   1. 7.1 Push the sealing ring into the ring groove by hand and align it.

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8. Calibrating Teflon sealing ring: 
   1. 8.1 Slide assembly sleeve T10133/8  -2  - from the tool set T10133 over the mounting cone -1  - onto the sealing ring.
   2. 8.2 Carefully slide assembly sleeve over the sealing ring.
   3. 8.3 Only slide on assembly sleeve as far as required until its rear end is covering the sealing ring -arrow  -.
   4. 8.4 Leave tool on the sealing ring for one minute. 

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9. Remove assembly sleeve and mounting cone.
10. Insert new spring clamp -2  - on the fuel injector -1  - check that it is fitted securely.

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11. Install the fuel injector immediately as the Teflon sealing ring can swell after a short time.
    1. 11.1 If the fuel injector -1  - cannot be installed immediately, a dowel sleeve -2  - must be pushed over the Teflon sealing ring. The dowel sleeve is fitted as protection on new injectors.

    The dowel sleeves for the (DFI) fuel injectors on the 981 also fit! 

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12. Align the fuel injectors in such a way that the position of the connector housing fits into the recess on the cylinder head cover.

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