Injector(S), Fuel: Installation
Due to the complexity of the fuel injection system used on this engine, refer to the Diesel Engine Diagnostics, and service any fuel system DTCs prior to replacing any fuel injectors. If no DTCs are present, refer to the Diesel Engine Diagnostic Test for Lack of Engine Power, and perform all steps as directed prior to replacing any fuel injectors.
Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only. DO NOT use any lubricating or sliding agents that contain water.
DO NOT use a brush to clean around the injector nozzle (2). DO NOT lubricate area around fuel injector nozzle. The fuel injector may become restricted with debris.
Be sure a NEW copper washer/seal (3) is installed on end of injector and the old seal is removed, before installing in cylinder head.
No force should be used in installing the fuel injector. Do not apply any pressure to the wire harness connector or the fuel return port during the installation process.
- Install a NEW
O-ring on the fuel injector return nipple.NOTE:
Use care not to get any grease on injector nozzle.
- Lubricate the Fuel injector body with Lubriplate all purpose white grease.
- Using a NEW
copper sealing washer (3), install the fuel injector into cylinder head.
- Install the fuel injector clamp (1), washer (3) and a NEW bolt (2) and tighten to 33 N.m (24 ft. lbs.).
- Remove the protective caps and install fuel injector fuel tubes. Refer to TUBE(S), FUEL, INSTALLATION .NOTE:
Be sure lock buttons (1) are in up position before positioning.
- Position female fittings on fuel return line to male fittings at each fuel injector.
- After positioning, push down on each lock button (1) to secure fuel return line to each fuel injector.
- Connect the fuel injector(s) wire harness connector (1).
- Connect the negative battery cable.
- Perform the injector classification procedure with a diagnostic scan tool.
- Start the engine and inspect for fuel leaks.
- Install the engine cover and tighten the four nuts to 7 N.m (62 in lbs.).