Fuel Injectors: Installing

NOTE:

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-.

Fig 1: Identifying Radial Adjustment & Support Ring

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-- 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-.

Fig 2: Identifying Assembly Cone T10133/5, New Teflon Seal & Fuel Injector

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-- Slide combustion chamber seal as far possible onto assembly cone T10133/5 using assembly sleeve T10133/6.

Fig 3: Identifying Assembly Sleeve T10133/6 And Combustion Chamber Seal Inserted On Assembly Cone T10133/5

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-- Turn assembly sleeve T10133/6 around and slide combustion chamber seal into groove.

NOTE:

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.

Fig 4: Identifying Calibrating Sleeve T10133/7

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-- 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.

Fig 5: Identifying Calibrating Sleeve T10133/8

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-- Pull sizing sleeve T10133/8 off again, turning it in the opposite direction.

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

NOTE:

The combustion chamber seal must not be oiled.

Fuel Injectors, Installing

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

Fig 6: Cleaning Bore In Cylinder Head With Nylon Cylinder Brush T10133/4

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-- Slide fuel injector into the bore cylinder head as far as stop using assembly drift T10133/9.

Fig 7: Identifying Fuel Injector Installation In Cylinder Head Using Assembly Drift T10133/9

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NOTE:

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 LOWER INTAKE MANIFOLD WITH FUEL RAIL .

-- Install upper section of the intake manifold. Refer to UPPER INTAKE MANIFOLD .