Injector(S), Fuel: Removal
Due to the complexity of the fuel injection system used on this engine, refer to the Diesel Engine Diagnostics, and service any fuel system DTCs prior to replacing any fuel injectors. If no DTCs are present, refer to the Diesel Engine Diagnostic Test for Lack of Engine Power, and perform all steps as directed prior to replacing any fuel injectors.
Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. DO NOT use any lubricating or sliding agents that contain water.
- Disconnect the negative battery cable.
- Remove the four nuts and the engine cover.NOTE:
Label the location of each high pressure fuel line with the cylinder in which it was removed.
- Remove the fuel tubes (5) from fuel rail (6) and fuel injectors (4) and install a protective cap on the fuel injector (7) and fuel rail.
- Disconnect the fuel injector(s) wire harness connector.NOTE:
The fuel injector common fuel return line is connected to the low pressure fuel circuit (5 bar/72 psi).
- A lock button (1) is used to secure the common fuel return line to each fuel injector. Use your fingers to lift up all four lock buttons (1) to unlock. After unlocking all four buttons, lift up fuel return line assembly to remove.
- Remove the fuel injector mounting bolt (2), washer (3) and the clamp (1).
- Using compressed air, thoroughly clean surface area in and around injector bore to prevent foreign material from falling into the injector bore after injector removal.NOTE:
Label the location of each fuel injector to the cylinder in which it was removed.
- Using your hand, pull the fuel injector (4) straight up from cylinder head for removal. After removing the injector, place a protective cap over the nozzle.
- If the fuel injector can't be removed by hand, install Fuel Injector Removal Tool (special tool #9552, Remover, Fuel Injector) (2) to top of fuel injector (1).
- Install Slide Hammer Tool (special tool #8941, Puller) (1) onto Fuel Injector Remover Tool (special tool #9552, Remover, Fuel Injector) (4). Tighten the lock nut (2). Remove the fuel injector from cylinder head.