Operation CHARM: Car repair manuals for everyone.

Fuel Injector






Fuel Injector

Special tools, testers and auxiliary items required

Tool Set (T10133)

The puller (T10133/2) was changed. It is now called the puller (T10133/2A). If the new tool is not available, the old one can be modified.

The puller (T10133/2) has been changed to puller (T10133/2A)

Procedure

- File a semi-circle using a round file (approximately 6 mm) as shown in the illustration.






The semi-circle allows the puller to slide farther on to the fuel injector, thus providing the puller with a larger contact surface.

- Mark the modified puller with an "A" at the end of the tool number.

Fuel Injector (Old Version)





1 Combustion chamber seal (Teflon seal), replace when installing, the seal must not be greased or handled with any other lubricants.
2 An intermediate ring shall replace the support ring; refer to fuel injector (new version).
3 Fuel injector
4 Spacer ring, replace if damaged
5 O-ring (replace, lubricate lightly with clean engine oil when installing)
6 Support ring (via this support ring, fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

Fuel Injector (New Version)





1 Intermediate ring, replace
2 Mount
3 Combustion chamber seal (Teflon seal), replace when installing, the seal must not be greased or handled with any other lubricants.
4 Fuel injector
5 Spacer ring, replace if damaged
6 O-ring (replace, lubricate lightly with clean engine oil when installing)
7 Support ring (via this support ring, fuel rail utilizes the force to hold the fuel injector in place in the cylinder head).

Removing

- Remove the intake manifold with the fuel rail. Refer to => [ Intake Manifold with Fuel Rail ] Intake Manifold with Fuel Rail.

- Cover the intake passages with a clean cloth.

If the fuel injectors remain stuck in the fuel rail, carefully pull them out.

- Remove the support element - A - downward and disconnect the connectors - arrows - from the fuel injectors.






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






- Install the removal tool (T10133/16) , turn the bolt - 1 - and remove the fuel injector.

Pay attention to the intermediate rings.

If new fuel injectors are not going to be installed, then clean the old injectors before installing. Refer to => [ Fuel Injector, Cleaning ] Service Precautions.

The combustion chamber seal (Teflon seal) must always be replaced before reinstalling the fuel injector. Refer to => [ Fuel Injector Teflon Seal ] Fuel Injector Teflon Seal.

Installing

The combustion chamber seal (Teflon seal) for the fuel injector must not be oiled or greased.

It is possible an opened intake valve may hinder the cleaning of the bores in the cylinder head. In this case, the engine must be rotated further by hand using a wrench on the crankshaft.

- Thoroughly clean the bores for the fuel injectors in the cylinder head using the nylon brush (T10133/4).






- Replace the fuel injectors combustion chamber seal (Teflon seal). Refer to => [ Fuel Injector Teflon Seal ] Fuel Injector Teflon Seal.

- Assemble the fuel injector with the parts from the repair kit.

- Press the fuel injector by hand into the cylinder head (free of oil and grease) as far as the stop. Make sure the fuel injectors are positioned - arrow - correctly inside the cylinder head.






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






- Install the support ring onto the fuel injector.

- Lightly lubricate the O-rings for the fuel injector with clean engine oil before installing

- Install the intake manifold with the fuel rail. Refer to => [ Intake Manifold with Fuel Rail ] Intake Manifold with Fuel Rail.