Fuel Injectors
Fuel Injectors
RH Fuel Injectors
LH Fuel Injectors
Removal
1. WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.
Shut the engine off and wait until the engine is cool or 5 minutes, whichever is longer, to allow the high-pressure fuel system pressure to bleed off and the fuel to cool.
2. Remove the LH or RH valve cover. For additional information, refer to Engine.
3. WARNING: Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal injury.
Make sure the ignition switch is in the OFF position.
4. Using the Fuel Injector Connector Disconnect Tool, disconnect the fuel injector electrical connectors. Detach the fuel charging wiring harness from the fuel rail.
5. If necessary, disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.
6. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps on any open orifices or tubes.
NOTE: Use a back-up wrench on the fuel injector fittings.
Remove and discard the fuel injector supply tube.
7. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
8. NOTICE: Failure to account for all fuel injector hold-down clamp assembly bolt retainers or pieces of retainers prior to placing the vehicle back in service may cause engine damage. A missing retainer can be ingested into the lube oil system causing severe engine damage.
NOTICE: To prevent engine damage, do not use air tools to remove the fuel injectors. The fuel injector hold-down clamp assembly bolt retainer that extracts the injector can dislodge and fall into the oil drain hole.
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.
Loosen the bolt, and remove the fuel injector hold-down clamp assembly and the fuel injector.
- Remove and discard the O-ring seal and soft steel combustion gasket.
9. Install a Fuel Injector Cup on the fuel injector nozzle and store the fuel injector in the Fuel Injector Holding Rack.
10. NOTE: If a fuel injector hold-down clamp assembly bolt retainer or piece of a retainer is missing from the fuel injector hold-down clamp assembly, it must be located prior to removing the shop towels.
Remove the shop towels.
Installation
1. NOTE: Lubricate the fuel injector and O-ring seal with clean engine oil.
Install a new O-ring seal and a soft steel combustion gasket on the fuel injector.
- Make sure the bead on the soft steel combustion gasket is facing the cylinder head.
2. NOTICE: Failure to tighten the injector correctly can lead to engine failure.
NOTICE: To prevent engine damage, do not use air tools to install the fuel injectors. The fuel injector hold-down clamp bolt retainer that extracts the injector can dislodge and fall into the oil drain hole.
NOTICE: If the fuel injector hold-down clamp assembly bolt retainer is damaged or missing, a new fuel injector hold-down clamp assembly must be installed, or the clamp assembly will not be able to remove the fuel injector.
Install the fuel injector, the fuel injector hold-down clamp assembly and the bolt.
- Tighten to 2 Nm (18 lb-in).
3. NOTE: Use a back-up wrench on the fuel injector fittings.
NOTE: Use a crowfoot wrench to aid in tightening the fuel injector supply tube.
Install the new fuel injector supply tube in the following sequence.
1. Remove the Fuel System Caps from the high-pressure fuel rail and the fuel injector one at a time prior to assembly of each tube.
2. Position the new fuel injector supply tube between the high-pressure fuel rail and fuel injectors and fully hand-start and seat the tube fittings onto the mating high-pressure fuel rail and fuel injector high-pressure connectors. Snug the fuel injector supply tube fittings using the inside-out step sequence (the 2 inside tubes then the 2 outside tubes).
- Calculate the correct torque wrench setting for the following torque.
- Using a torque adapter, tighten to 2 Nm (18 lb-in).
3. Tighten the fuel injector hold-down clamp bolt.
- Tighten to 38 Nm (28 lb-ft).
4. NOTE: Pre-tighten the fuel injector fitting first, then the fuel rail fitting.
Pre-tighten the fuel injector supply tube fittings.
- Calculate the correct torque wrench setting for the following torque.
- Using a torque adapter, tighten to 12 Nm (106 lb-in).
5. NOTE: Place a visible mark with a permanent marker on the high-pressure fuel rail and fuel injector threaded connection. Turning the tube fittings one flat of the nut is equal to 60 degrees.
Final tighten the fuel injector supply tube fittings.
- Tighten the fittings 60 degrees.
4. If necessary, connect the FRP sensor electrical connector.
5. Connect the fuel injector electrical connector.
6. Install the LH or RH valve cover. For additional information, refer to Engine.
7. Bleed the high-pressure fuel system. For additional information, refer to Fuel Delivery and Air Induction.
8. NOTE: Clearing the DTCs or Keep Alive Memory (KAM) does not reset the adaptive values in the PCM.
If fuel injector(s) were replaced, clear the fuel injector adaptive tables from the PCM, using the scan tool. For additional information, refer to Computers and Control Systems Information.