Fuel Injector: Service and Repair

Fuel Injectors

Special tools, testers and auxiliary items required

• Tool Set (T10133)

Removing


There is a risk of injury because the fuel is under very high pressure.

• Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure.

- Reduce fuel pressure in high pressure area. Refer to => [ Before Opening High Pressure Fuel Injection System ] Service and Repair.

- Remove the supercharger.

- Remove the affected intake manifold lower section. Refer to => [ Intake Manifold, Lower Section, with Fuel Rail ] Intake Manifold, Lower Section, with Fuel Rail.

- Guide the puller (T10133/2A) in the groove on the fuel injector.






- Mount the removal tool (T10133/16) on the puller, turn the screw - 1 - and remove the fuel injector.

Disassemble the Fuel Injector.

- Remove the support ring - 4 -, O-ring - 3 - and spacer ring - 2 - from the fuel injector - 1 -.






- Remove the circlip - 7 - and upper sealing washer - 5 - and lower sealing washer - 6 -.

- Carefully remove the old combustion chamber seal - 8 - by cutting the sealing ring with a knife and prying it open with a small screwdriver.

- 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 combustion chamber seal and O-ring.

• Replace spacer ring if damaged.

• Lightly coat the fuel injector O-rings with clean engine oil.

• Install the cylinder at same cylinder.

- Clean bore in cylinder head with nylon cylinder brush (T10133/4).






- Place assembly cone (T10133/5) with new combustion chamber seal - 1 - from the repair kit onto the fuel injector - 2 -.






- Slide combustion chamber seal as far possible onto (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 (T10133/8) off again, turning it in the opposite direction.

- Install the parts form the repair kit on the injector valve - 1 -:






2 Spacer ring
3 O-ring
4 Support ring
5 Upper sealing washer - note installation position
6 Lower sealing washer - note installation position
7 Circlip - do not overstretch

- Coat the new O-ring with clean engine oil before installing.

• The combustion chamber seal - 8 - must not be oiled.

- Press the fuel injector by hand into the bore in the cylinder head (free of oil and grease) until it stops. Make sure fuel injectors are positioned correctly in cylinder head.

• The fuel injector must not be difficult to install. If necessary, wait as the combustion chamber seal continues to pull itself together.

• Check fuel injectors for correct seating and installation position in cylinder head.

• If it is difficult to install the fuel injector by hand use the puller (T10133/2A) - 2 - with the hammer (T10133/3).






• The electrical connection of the fuel injector must engage in the intended recess of the cylinder head.

Further installation is performed in reverse order of removal, noting the following:

- Install the lower intake manifold section. Refer to => [ Intake Manifold, Lower Section, with Fuel Rail ] Intake Manifold, Lower Section, with Fuel Rail.

- Install the supercharger.