Removal and Replacement

WARNING:
- HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS. THIS MAY BE AS HIGH AS 1600BAR (23,200 PSI). USE EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH. INSPECT FOR HIGH-PRESSURE LEAKS WITH A SHEET OF CARD BOARD. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM.
- NO SPARKS, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.

REMOVAL

NOTE: The engine must be lowered in the vehicle to remove the fourth and fifth cylinders fuel injectors.

1. Disconnect negative battery cable.
2. Remove engine cover.
3. Raise and suitably support the vehicle.
4. Remove lower radiator deflector plate.
5. Drain cooling system.
6. Remove turbocharger down pipe assembly.
7. Remove oil dipstick tube retaining bolt and pull tube from oil pan.
8. Lower vehicle.
9. Remove upper radiator hose.
10. Remove air cleaner box assembly and hoses.
11. Remove charge air cooler inlet hose.
12. Remove charge air cooler to turbocharger inlet adaptor.
13. Remove turbocharger to right engine mount bracket.
14. Disconnect steering coupler at gear box (RHD Only).
15. Remove battery.
16. Unclip PDC from battery tray and set aside.
17. Remove battery tray .
18. Remove power steering reservoir.
19. Remove charger air cooler outlet hose.
20 Remove intake manifold to left engine mount bracket.
21. Evacuate air conditioning system.
22. Disconnect air conditioning suction / discharge lines at A/C compressor.
23. Disconnect pedal position sensor electrical connector.
24. Unplug injector electrical connectors.
25. Remove fuel / water separator to intake manifold retaining bolts.
26. Support engine with hoist.
27. Remove engine mount through bolts.
28. Remove right engine mount sill plate.

NOTE: Counterhold injection lines with wrench socket at threaded connections of injectors.

29. Disconnect fuel injector high pressure line.
30. Remove fuel injector retaining bolt and tension claw.
31. Suitably lower engine to gain fuel injector access and remove injector.

NOTE: If injectors are tight, remove with extraction claw in place of tensioning claw. If extraction claw contacts cylinder head cover, remove cylinder head cover. If necessary, remove injectors with threaded adaptor and discard injector.

Fuel Injector Removal/Installation:

32. Remove injectors.
33. Clean injectors and recesses.

INSTALLATION

1. Clean injectors and recesses.
2. Coat injector body with anti seize lubricant then install injectors with new seals.
3. Install tensioning claws with new screws at injectors. Tighten screws in two stages, 7 N.m (62 lbs. in.) then 90°.

NOTE: If locking clamp has been pulled off at injector, the locking clamp must be replaced.

4. Position fuel return line at injectors and secure locking clamps.

NOTE: Counterhold injection lines with wrench socket at threaded connections of injectors.

5. Install high pressure injection lines.
6. Reconnect injector electrical connectors.
7. Raise engine and install right sill plate.
8. Install engine mount through bolts and tighten to 40 N.m (30 lbs. ft.).
9. Install fuel/water separator to intake manifold retaining bolts.
10. Connect pedal position sensor electrical connector.
11. Connect air conditioning lines to A/C compressor.
12. Install intake manifold to left engine mount bracket.
13. Install charge air cooler outlet hose.
14. Install power steering reservoir.
15. Install battery tray.
16. Connect PDC to battery tray.
17. Install battery .
18. Connect steering coupler at gear box (RHD Only).
19. Install turbocharger to right engine mount bracket.
20. Install charge air cooler to turbocharger inlet adaptor.
21. Install charger air cooler inlet hose.
22. Install air cleaner box assembly and hoses.
23. Install upper radiator hose.
24. Raise vehicle.
25. Install dipstick tube into oil pan and tighten retaining bolt.
26. Install turbocharger down pipe assembly.
27. Close cooling system drain.
28. Install lower radiator deflector plate.
29. Lower vehicle.
30. Connect negative battery cable.
31. Install engine cover.
32. Fill cooling system with the correct mixture to the proper level.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.

33. Start engine and inspect for leaks.
34. Recharge air conditioning system.