Fuel Injectors, Removing And Installing: Removing

• Only remove the fuel injectors when the engine is cold.
• Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

-- Remove the fuel rail. Refer to FUEL RAIL, REMOVING AND INSTALLING .

• If the fuel injectors are stuck in the fuel rail, carefully pull out the fuel injectors from the fuel rail.

-- Remove the fuel injectors from the cylinder head.

Remove jammed fuel injectors as follows: 

-- Cylinder 1: Piston Cooling Nozzle Control Valve -N522-, Removing. Refer to Piston Cooling Nozzle Control Valve -N522-, REMOVING AND INSTALLING .

-- Cover the open intake channels with a clean cloth.

-- Remove the support ring -5- from the fuel injector -2-.

-- Push the : T10133/23  -2- over the fuel injector.

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-- Carefully tap the fitting sleeve with a plastic mallet -1- to loosen the fuel injector.

• Use a torque wrench to remove the fuel injector.
• Adjust to 5 Nm on the torque wrench
• The fuel injectors may be damaged if the tightening specifications are not observed.

-- Fuel injector, Bosch: slide in the : T40433/1  -2- into the fuel injector groove.

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-- Fuel injector, Continental: slide in the : T40433/2  -2- into the fuel injector groove.

-- Install the removal tool : T10133/16A  .

-- Remove the fuel injector by using the torque wrench to turn the bolt -1-.

-- If the tightening specification limit of >>5 Nm<< is achieved without the fuel injector loosening, remove the puller and loosen the fuel injector with the sleeve.

-- Repeat this on each fuel injector.

Disassembling the Fuel Injector

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

-- Carefully remove the old combustion chamber seal -1- by cutting the combustion chamber seal with a knife or widen it with a small screwdriver and remove it forward.

5 -  Support Ring

-- Clean the seal groove in the area of the seal -arrow-. Remove any deposits (coking) with a brass wire brush.

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• Make sure that the groove of the fuel injector does not become damaged. If the groove is damaged, the fuel injector must be replaced.