Fuel Injector Replacement

Fuel Injector Replacement

Tools Required

^ EN-47909 Injector Bore and Sleeve Kit
^ J 44639 Fuel Injector Puller

Removal Procedure

Important: Refer to Computers and Control Systems Component Views for fuel injector locations. Failure to identify the correct cylinder will result in misdiagnosis.





1. Remove the lower valve cover.

Important: When the fuel injector pressure lines are removed, debris may fall into the fuel injector inlet fitting. Remove any debris from the inlet fitting of the fuel injector.

Important: Confirm which side of the banjo washer have the largest outer diameter.

2. Remove the fuel injector pressure line from fuel injectors.
3. Remove the bolt from the fuel injector bracket.





4. Install J 44639 (2) onto the injector retainer bracket.
5. Install a wrench onto J 44639 (2) and pry away from the fuel injector (1).
6. Remove the fuel injector(s).
7. Remove the copper compression washer from the injector hole if the washer was not removed with the injector.

Installation Procedure





1. If the fuel injector sleeve was pulled from the cylinder head when removing the injector(s), refer to Fuel Injector Nozzle Tube Sleeve Replacement.
2. Install a NEW O-ring onto the fuel injector(s).
3. Lubricate the O-ring with clean engine oil.
4. Install a NEW copper washer into the fuel injector bore in the cylinder head.
5. Install the fuel injector with injector bracket.

NOTE: Refer to Fastener Notice in Service Precautions.

6. Install the injector bracket bolt.

Tighten
Tighten the bolt to 50 Nm (37 lb ft).





7. Install the return pipe assembly.
8. Install the fuel injector return line to injector eye bolts and washers. Lubricate the washers with diesel fuel prior to installing.

Tighten
Tighten the fuel injector line to injector eye bolts to 16 Nm (12 lb ft).

9. Install the fuel injector return line to cylinder head eye bolts and washers. Lubricate the washers with diesel fuel prior to installing.

Tighten
Tighten the fuel injector return line to cylinder head eye bolts to 16 Nm (12 lb ft).

10. Install the lower valve cover.