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 and isolate the negative battery cable.
- Remove the engine cover.
- Disconnect the fuel injector wire harness connector (1) and position aside wire harness (2).
- Lift up on locking retaining tab (1) to unlock for each fuel return line.
- Disconnect the fuel return hose (3) by wiggling hose free from the fuel injector.
- Loosen the fuel tubes union nut (1, 3), and remove fuel tubes (2). Install protective cap on the fuel injectors and fuel rail.
- 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.
- Remove bolt (2) and injector clamp (3).
- Using your hand, pull fuel injector (1) straight up from cylinder head for removal. After removing the injector, place a protective cap over the nozzle and cylinder head.
- If injector can't be removed by hand, install the (special tool #2014600140, Remover, Fuel Injector) (2) with (special tool #C-3752, Slide Hammers)and install it on the of fuel injector (1) and remove fuel injector.