Fuel Injectors

Fuel Injectors









Removal

1. Remove the valve covers. For additional information, refer to Engine.

2. Disconnect the fuel injector electrical connector.





3. Loosen the crankcase-to-head tube(s).





4. Position the crankcase-to-head tube and separate the tube.
- Allow the lower section to go back down.





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. Remove the port plug from the high-pressure oil rail.
- Inspect the port plug O-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 Injector Connector Release 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 to remove or install the fuel injectors.

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 [1][2]Fuel Injector Sleeve.

NOTE: There is no need to drain the fuel rail.

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.
- Remove and discard the O-ring seals and copper washer.





Installation

1. NOTE: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.

NOTE: Lubricate the fuel injector and O-ring seals liberally with clean engine oil.

Install new O-ring seals and a copper washer on the fuel injector.





2. NOTICE: Failure to tighten the injector correctly can lead to engine failure.

NOTICE: To prevent engine damage, do not use air tools to remove or install the fuel injectors.

Assemble the fuel injector hold down and bolt on the fuel injector and install the assembly.

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





3. 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 clean engine oil to the top fuel injector O-ring seals.





6. NOTE: Apply clean engine oil to the D-ring seal, prior to installing.

Position the lower section of the crankcase-to-head tube in the engine.





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. Install the crankcase-to-head tube(s).
- Tighten to 82 Nm (60 lb-ft).





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. For additional information, refer to Engine.