Renewing seals on injectors

Special tools and workshop equipment required

• Tool set - T10133-

Procedure

Renewing Teflon seal

Remove air filter ⇒ 1.3 Removing and installing air filter housing.

Remove regulating flap control unit - J808- and throttle valve module - J338- ⇒ 2.2 Removing and installing regulating flap control unit - J808- and throttle valve module - J338-.

• Remove intake manifold and lower part of intake manifold ⇒ 2.1 Assembly overview - intake manifold.
• Remove injectors ⇒ 3.2 Removing and installing injectors.
• Clean injector carefully.
• Carefully cut open seal with a knife as shown -arrow-. Avoid contact between knife blade and valve body under all circumstances.

• Remove old seal and clean seal groove in area of seal -arrow-. Remove coking deposits using a brass wire brush.

• Fit new oil seal -1- onto assembly cone - T10133/5-. Using assembly sleeve - T10133/6- (knurled end faces seal -1-), gently slide seal onto assembly cone - T10133/5- as far as possible.

• Turn assembly sleeve - T10133/6- around (knurl no longer points to seal), and push seal -1- to end of assembly cone - T10133/5-.
• Now place assembly cone - T10133/5- with seal onto injector from front. Slide seal further onto injector using assembly sleeve - T10133/6-.

The seal is not yet seated in its groove.

• Remove assembly sleeve - T10133/6- and assembly cone - T10133/5-.
• Slide seal into annular groove by hand.
• Position spacer sleeve - T10133/11- onto valve body.
• Now push calibrating sleeve - T10133/7- over seal to stop onto spacer sleeve - T10133/11-.

• Pull off calibrating sleeve - T10133/7- again.
• Now push calibrating sleeve - T10133/8- over seal to stop onto spacer sleeve - T10133/11-.
• Pull off calibrating sleeve - T10133/8- again.

Now the Teflon seal has correct installation dimensions.

Renewing support washer

• Remove O-ring -3-.
• Cut support washer -2- open with a small pair of side cutters and remove it.

• Pull spring element -1- off injector and replace with retaining plate - T10133/12-.
• Place new support washer -1- onto assembly cone - T10133/13- and position onto injector as shown.

• Slide support washer -1- into first groove -arrow- on injector using calibration sleeve - T10133/17- (knurled side points to injector).
• Now turn calibration sleeve - T10133/17- around (knurled side no longer points to injector). Slide calibration sleeve over support washer -1- in direction of -arrow- to stop on retaining plate - T10133/12-.
• Pull calibrating sleeve - T10133/17- down again.

The support washer now has correct installation dimensions.

• Now position a new spring element -1- for retaining plate - T10133/12- and position a new O-ring -3- in front of support washer -2-.

• Install injectors ⇒ 3.2 Removing and installing injectors.
• Place lower part of intake manifold carefully on injectors and tighten securing bolts to 20 Nm ⇒ 2.1 Assembly overview - intake manifold.
• Install intake manifold ⇒ 2.1 Assembly overview - intake manifold.
• Install regulating flap control unit - J808- and throttle valve module - J338- ⇒ 2.2 Removing and installing regulating flap control unit - J808- and throttle valve module - J338-.

Install air filter ⇒ 1.3 Removing and installing air filter housing.

Further installation is carried out in reverse order of removal.