Fuel Injectors, Removing And Installing: Installing

• Use the complete repair kit when installing.
• Replace the support ring after removing.
• Replace the combustion chamber seal before reinstalling the fuel injector.

-- Clean the hole in the cylinder head with the Brush: T10133/4  -item A-.

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-- When installing a fuel injector, use a clean towel to clean combustion residue from the groove for the combustion chamber seal and the fuel injector shaft.

Install the Combustion Chamber Seal, Fuel Injector, Bosch

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-- Slide the Calibration Sleeve: T40433/5  on the fuel injector -1-.

• Pay attention to the direction of the arrow.

-- Put the Fuel Injector Removal Tool - Assembly Pin: T40433/3  together with the new combustion chamber seal -2- on the fuel injector.

-- Push on the combustion chamber seal using the Removal Tool - Guide Sleeve: T40433/4  up to the seal.

-- Remove the Fuel Injector Removal Tool - Assembly Pin: T40433/3  and Removal Tool - Guide Sleeve: T40433/4  from the fuel injector.

When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. After pushing it on, it must be tightened again, as described in the following.

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-- Slowly remove the Fuel Injector Removal Tool - Calibration Sleeve: T40433/5  with a gentle rotational movement (approximately 180°) from the fuel injector -1-.

Install the Combustion Chamber Seal, Fuel Injector, Continental

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-- Put the Fuel Injector Removal Tool - Assembly Pin: T40433/3  together with the new combustion chamber seal -2- on the fuel injector -1-.

-- Push on the combustion chamber seal using the Removal Tool - Guide Sleeve: T40433/4  up to the first seal.

-- Remove the Fuel Injector Removal Tool - Assembly Pin: T40433/3  and Removal Tool - Guide Sleeve: T40433/4  from the fuel injector.

When pushing the combustion chamber seal onto the fuel injector, the seal spreads open. After pushing it on, it must be tightened again, as described in the following.

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-- Press the Fuel Injector Removal Tool - Calibration Sleeve: T40433/5  with a gentle rotational movement (approximately 180°) all the way onto the fuel injector -1-.

• Pay attention to the direction of the arrow.

-- Remove the Fuel Injector Removal Tool - Calibration Sleeve: T40433/5  again, with a rotational movement in the opposite direction.

Continuation for All: 

-- Coat the new O-ring -4- with clean engine oil before installing the fuel injector -2-.

• The combustion chamber seal -1- must not be oiled.

-- Press the fuel injector by hand all the way in the oil and grease free opening for the cylinder head. Make sure the fuel injectors are positioned -arrow- correctly inside the cylinder head.

• The tab -1- and the opening -arrow- must be aligned in the cylinder head.
• The fuel injector must not be difficult to install. Otherwise wait as the combustion chamber seal continues to pull itself together.

-- Install the support ring onto the fuel injector.

-- If removed, install the Piston Cooling Nozzle Control Valve -N522-. Refer to Piston Cooling Nozzle Control Valve -N522-, REMOVING AND INSTALLING .

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