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 the puller (T10133/2-A). If the new tool is not available, the old one can be modified.
Modify puller (T10133/2) to create the puller (T10133/2-A).
Special tools, testers and auxiliary items required
• Round file approximately 6 mm
- File the semi-circle as shown in the illustration. The semi-circle allows the tool to slide farther onto the fuel injector, thus providing the tool with a larger contact surface.
- Mark 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 ] Service and Repair.
• To reduce remaining residual pressure, lay a clean cloth around the connector and carefully loosen connector.
- Remove upper section of the intake manifold. Refer to => [ Intake Manifold, Upper Section ] Intake Manifold, Upper Section.
- Remove 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 puller (T10133/2A) in the groove on the fuel injector.
- Then position the trim removal wedge (T10133/16) and remove the fuel injector by loosening 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.
• Re-insert injector lines at same cylinder.
- Clip 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 assembly sleeve (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 sizing sleeve (T10133/7) with a slight turning motion (approximately 180°) onto the fuel injector until it stops.
- Pull sizing sleeve (T10133/7) off again, turning it in the opposite direction.
- Press sizing sleeve (T10133/8) with a slight turning motion (approximately 180°) onto the fuel injector until it stops.
- Pull 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 installation is in reverse order of removal, note the following:
- Install lower section of the intake manifold. Refer to => [ Intake Manifold, Lower Section, with Fuel Rail ] Intake Manifold, Lower Section, With Fuel Rail.
- Install upper section of the intake manifold. Refer to => [ Intake Manifold, Upper Section ] Intake Manifold, Upper Section.