Fuel Injector Sleeve

Fuel Injector Sleeve









Removal

1. Remove the engine from the vehicle.

2. Mount the engine on the Car/Truck Engine Stand.





3. NOTE: Mark the location of the stud bolts.

If replacing a RH fuel injector sleeve, remove the 6 stud bolts, 5 bolts and the RH valve cover.





4. Remove the crankcase-to-head tube(s).





5. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support these components.

Remove the 9 bolts and the high-pressure oil rail.





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 High-Pressure Supply Tube Remover, remove the lower crankcase to head tube.





7. Inspect the D-ring seals for damage (nicks, cuts and gouges). If damaged, replace the crankcase-to-head tube.





8. NOTICE: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.

Using the Injector Connector Release Tool, push the fuel injector electrical connector out of the rocker arm carrier.





9. NOTE: The bolt is part of the fuel injector hold-down assembly.

Loosen the bolt and fuel injector hold-down assembly and the fuel injector.





10. Fill the lower portion of the fuel injector sleeve with grease to prevent metal from falling into the cylinder.

11. NOTE: The fuel injector sleeve is made of stainless steel. Lubrication of the fuel injector sleeve removal tap is necessary. Without lubrication, excessive force will be needed to get the tap started and damage to the tap can occur.

Insert the Fuel Injector Sleeve Remover tap and pilot into the cylinder head fuel injector bore. Thread the injector sleeve tap one and a half to 2 turns.





12. Install the Fuel Injector Sleeve Remover tool into the threaded sleeve. Using the Slide Hammer, remove the fuel injector sleeve from the cylinder head fuel injector bore.
- Discard the fuel injector sleeve.





13. NOTE: Cylinder head removed for clarity.

Using the Fuel Injector Sleeve Brush Set, clean the fuel injector bore of deposits and hardened sealant.





14. NOTE: Cylinder head removed for clarity.

Remove the fuel rail plug. Clean the fuel gallery with a wire brush. Use filtered compressed air to remove foreign material from the gallery. Install the fuel rail plug.





Installation

1. Verify the fuel injector bore is clean and dry.

2. Position the new fuel injector sleeve onto the Fuel Injector Sleeve Installer. Apply threadlock or equivalent to the very bottom (smallest diameter) and very top (largest diameter) flat areas.





3. Position the Fuel Injector Sleeve Installer into the cylinder head fuel injector bore. Seat the fuel injector sleeve in the fuel injector bore, using a rubber mallet. If any sealant gets into the inside of the injector sleeve, it must be cleaned out before it hardens.





4. NOTICE: If the fuel injector oil inlet D-shape O-ring is damaged, a new fuel injector must be installed.

Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-ring seals liberally with clean engine oil.





5. 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.

- Tighten to 35 Nm (26 lb-ft).





6. 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.





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 to the top fuel injector D-ring seals before installing the high-pressure oil rail.

Position the high-pressure oil rail on the injectors.

- Place the high-pressure oil rail on top of the carrier so that the 4 single ball tubes are engaging the fuel injector lead angle.

- Insert 3 guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and 1 in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.

- Manually press the high-pressure oil rail into the fuel injectors.

- Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface.

- Loosely install the 6 high-pressure oil rail bolts.





8. Remove the 3 guide bolts, install the remaining high-pressure oil rail bolts and tighten the 9 bolts in the sequence shown.
- Tighten to 13 Nm (115 lb-in).





9. Apply clean engine oil to the D-ring seals and reassemble the crankcase-to-head tube if necessary. Install the crankcase-to-head tube(s).
- Tighten to 82 Nm (60 lb-ft).





10. If removed, install the RH valve cover, 5 bolts and 6 stud bolts.
- Tighten to 13 Nm (115 lb-in).





11. Remove the engine from the Car/Truck Engine Stand.

12. Install the engine in the vehicle.