Fuel Injector: Service and Repair
Fuel Injectors
Special tools, testers and auxiliary items required
• Tool Set (T10133)
• The puller (T10133/2) was changed and is now called puller (T10133/2-A). If the new tool is not available, the old one can be modified.
Modify the puller T10133/2 to create the puller T10133/2-A.
Special tools, testers and auxiliary items required
• Round file approximately 6 mm
- File the semicircle as shown in the illustration. The semicircle allows the tool to slide farther onto the fuel injector, thus providing the tool with a larger contact surface.
- Mark the modified tool with an A at the end of the tool number.
High Pressure Fuel Injector, Assembly Overview
1. Radial adjustment - Replace if damaged
2. Combustion chamber seal (Teflon seal) - replace, the seal must not be greased or be handled with any other lubricant during installation
3. Groove on fuel injector
4. Spacer ring - Replace if damaged
5. O-ring - replace, lightly coat with clean engine oil during installation
6. Support ring - fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head
Removing
There is a risk of injury because the fuel is under very high pressure.
• The fuel pressure must be reduced to residual pressure before opening the high pressure area of the fuel injection system. Refer to => [ Before Opening High Pressure Fuel Injection System ] Before Opening High Pressure Fuel Injection System.
• To reduce remaining residual pressure, lay a clean cloth around the connector and carefully loosen connector.
- Remove the upper section of the intake manifold. Refer to => [ Intake Manifold, Upper Section ] Intake Manifold, Upper Section.
- Remove the affected intake manifold lower section. Refer to => [ Intake Manifold, Lower Section, with Fuel Rail ] Intake Manifold, Lower Section, With Fuel Rail.
If the fuel injectors cannot be pulled out of the cylinder head by hand, proceed as follows:
- Using a screwdriver, bend the retaining tabs - 1 - of the radial adjustment aside - arrow - and pull the support ring - 2 - from the fuel injector.
- Guide the (T10133/2A) in the groove on the fuel injector.
- Then position the trim removal wedge (T10133/16) and remove the fuel injector by loosening the bolt - 1 -.
• When setting the puller in place, the radial adjustment can be destroyed, because the retaining tabs break.
- Carefully remove the old combustion chamber seal - arrow -, thereby cutting seal open with a knife or spreading seal open with a small screwdriver and pulling it forward and off.
- Make sure that the groove of the fuel injector does not become damaged. If the groove is damage, the fuel injector must be replaced.
Installing
• Replace the combustion chamber seals and O-rings.
• Replace the spacer ring and radial adjuster if damaged.
• Lightly coat fuel injector O-rings with clean engine oil.
• Install the cylinder at same cylinder.
- Clip the radial adjustment - 1 - to the support ring - 2 -.
- When re-installing a fuel injector, use a clean cloth to clean combustion residue from the groove for combustion chamber seal and the shaft of the fuel injector.
- Place assembly cone (T10133/5) with new combustion chamber seal - 1 - on fuel injector - 2 -.
- Slide combustion chamber seal as far possible onto assembly cone (T10133/5) using assembly sleeve (T10133/6).
- Turn (T10133/6) around and slide combustion chamber seal into groove.
• When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. Therefore after pushing it on, it must be tightened again in 2 steps, as follows.
- Press the sizing sleeve (T10133/7) with a slight turning motion (approximately 180°) onto the fuel injector until it stops.
- Pull the (T10133/7) off again, turning it in the opposite direction.
- Press the sizing sleeve (T10133/8) with a slight turning motion (approximately 180°) onto the fuel injector until it stops.
- Pull the sizing sleeve (T10133/8) off again, turning it in the opposite direction.
- Coat the new O-ring with clean engine oil before installing.
• The combustion chamber seal must not be oiled.
Fuel Injectors, Installing
- Clean bore in cylinder head with nylon cylinder brush (T10133/4).
- Slide fuel injector into the bore cylinder head as far as stop using assembly drift (T10133/9).
• The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.
- Make sure fuel injectors are correctly positioned in cylinder head.
• The electrical connection of the fuel injector must engage in the intended recess of the cylinder head.
The rest of the installation is in reverse order of removal, note the following:
- Install the lower section of the intake manifold. Refer to => [ Intake Manifold, Lower Section, with Fuel Rail ] Intake Manifold, Lower Section, With Fuel Rail.
- Install the upper section of the intake manifold. Refer to => [ Intake Manifold, Upper Section ] Intake Manifold, Upper Section.