Fuel Injector: Installation

Fig 1: FUEL INJECTOR AND COMPONENTS

Courtesy of DAIMLERCHRYSLER CORP.

1 - FUEL RETURN LINE

2 - ONE WAY VALVE

3 - RETAINING RING

4 - WASHER

5 - O-RING

WARNING: HIGH - PRESSURE LINES DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS. THIS MAY BE AS HIGH AS 1600BAR (23,200 PSI.). USE EXTREME CAUTION WHEN INSPECTING FOR HIGH - PRESSURE FUEL LEAKS. FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH. INSPECT FOR HIGH - PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM.

NOTE: DO NOT use a brush to clean around the injector nozzle. DO NOT lubricate area around injector nozzle. The injector may become restricted with debris.

NOTE: Be sure a new copper washer/seal is installed on end of injector before installing in cylinder head.

NOTE: Apply antiseize compound to injector body.

Install fuel injector in cylinder head with new seal and O-ring.
Install fuel injector retainer and bolt. See Fig 1. Torque bolt to 32.4 N.m.
Install fuel injector high pressure line.
Install fuel return line to injector. See Fig 1.
Connect fuel injector electrical connector.
Install engine cover and bracket assembly (Refer to ENGINE COVER - INSTALLATION) , (Refer to ENGINE COVER - INSTALLATION) or (Refer to ENGINE COVER - INSTALLATION) .
Connect negative battery cable.
Start the engine, allow to warm, Turn Off the Ignition , Inspect for leaks.