Fuel Injectors
Fuel Injectors
Special Tool(s)
Material
Removal
All vehicles
1. Remove the valve covers.
2. Disconnect the fuel injector electrical connector.
Late build vehicles
3. Remove the crankcase-to-head tube(s).
All vehicles
4. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
NOTE: Use a tool like the KD Tool #58965 or Lisle T30 to avoid interference with the evaporator case.
Remove the bolts and the high-pressure oil rail.
Early build vehicles
5. NOTE: The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.
Remove the crankcase-to-head tube(s).
Late build vehicles
6. NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.
If the crankcase-to-head tube separated, using the special tool, remove the lower crankcase-to-head tube.
All vehicles
7. NOTE: Late build shown, early build similar.
Inspect the D-ring seals for damage (nicks, cuts and gouges). If damaged, replace the crankcase-to-head tube.
8. Remove the port plug from the high-pressure oil rail.
- Inspect the port plug 0-ring seals for damage (nicks, cuts and gouges). If damaged, replace the port plug.
9. NOTICE: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
10. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
11. NOTICE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors. The snap ring that extracts the fuel injector can dislodge and fall off.
NOTICE: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system causing severe engine damage.
NOTE: There is no need to drain the fuel rail.
NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve. For additional information, refer to Fuel Injector Sleeve in this section.
NOTE: Use a tool like Snap-On SDMT440 torx to avoid damaging the fuel injector plastic and to avoid interference with the evaporator case.
NOTE: The bolt is part of the fuel injector hold-down assembly.
Loosen the bolt and remove the bolt and fuel injector hold-down assembly and the fuel injector.
Installation
All vehicles
1. NOTICE: If the fuel injector oil inlet D-shaped 0- ring is damaged, a new fuel injector must be installed.
Install new 0-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and 0-ring seals liberally with clean engine oil.
2. NOTICE: Failure to tighten the injector properly can lead to engine failure.
NOTICE: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
Assemble the fuel injector hold-down and bolt on the fuel injector and install the assembly.
3. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.
Remove the shop towels.
4. NOTICE: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
Install the fuel injector electrical connector into the rocker carrier.
5. Apply engine oil to the top fuel injector 0-ring seals.
Early build vehicles
6. NOTICE: To prevent engine damage, check to make sure the crankcase-to-head tube assemblies bottom out in the branch tube assembly. The oil rail, crankcase-to-head tube and the fuel injectors will not function correctly if these tubes are not bottomed out
Apply clean engine oil to the D-ring seals and install the crankcase-to-head tube(s).
All vehicles
7. NOTICE: Using the bolts to push the high-pressure oil rail into the fuel injectors can damage the fuel injectors and high-pressure oil rail.
NOTE: Apply clean engine oil on the tubes prior to installing the high-pressure oil rail.
Position the oil rail on the fuel injectors.
- Place the oil rail on top of the carrier so that the four single ball tubes are engaging the injector lead angle.
- Insert three guide bolts, two on the ends of the straight side of the oil rail and one in the middle of the wavy side of the rail. Install the guide studs six to seven turns.
- Manually press the oil rail into the fuel injectors.
- Make sure that the oil rail mounting feet are flat against the mounting surface.
- Loosely install the six bolts.
8. Install the oil rail retaining bolts.
- Remove the three guide bolts.
- Loosely install three remaining bolts.
- Tighten the nine bolts in the sequence shown.
Late build vehicles
9. Apply clean engine oil to the D-ring seals and reassemble the crankcase-to-head tube. Install the crankcase-to-head tube(s).
All vehicles
10. Apply clean engine oil to the port plug seals and install the port plug in the high-pressure oil rail.
Tighten to 82 Nm (60 lb-ft).
11. Connect the fuel injector electrical connector.
12. Install the valve covers.