Diesel Data: Automotive Repair

Fuel Injector Replacement




REMOVAL
1. Fuel system pressure release must be performed prior to service. Service and Repair
2. Disconnect negative battery cable, and remove air cleaner.
3. Remove the screw holding down the injector cap and with 2 small screwdrivers, lift the top cap off the injector.

Fuel Injector Removal:




4. Place a small screwdriver in the hole in the front of the electrical connector and gently pry the injector from the throttle body. Make sure the injector O-ring comes out of the throttle body with the injector.

Fuel Injector Removed:




INSTALLATION
1. Replace the O-rings on the injector (a new injector may already have the upper O-ring installed).

Fig. 4 Fuel Injector Installation:




2. After applying a light coat of oil to the injector O-rings, install the injector in the throttle body cup and align the wiring terminals with the injector cap fastener hole.
3. Install the injector cap with the locating notch aligned with the locating lobe on the injector top.

Fig. 5 Fuel Injector Cap Installation:




4. Rotate the injector and cap to line up the attachment hole. Install the fastening screw and torque to 4-5 Nm (35-45 lb-in)
5. Connect the negative battery cable, pressurize system and check for leaks.