Removal and Replacement

Fuel Injector Removal/Installation:

REMOVAL

WARNING: 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.

NOTE: When removing injectors, the seal rings and retaining stretch bolts must always be replaced. Coat the injector body with the anti- seize compound before installing. Keep lubricant away from the injector nozzle.

1. Disconnect negative battery cable.
2. Remove engine cover (Refer to ENGINE - REMOVAL).
3. Remove the fuel return hose locking clamps at the injector and remove return hose.
4. Disconnect the injector electrical connector.

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

5. Disconnect fuel injector high pressure line .
6. Remove fuel injector retaining bolt and tension claw, then remove the injector and seal.

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.

8. Clean injectors and recesses (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - STANDARD PROCEDURE).

INSTALLATION

WARNING: 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.

NOTE: When removing injectors, the seal rings and retaining stretch bolts must always be replaced. Coat the injector body with the anti- seize compound before installing. Keep lubricant away from the injector nozzle.

1. Clean injectors and recesses (Refer to FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - STANDARD PROCEDURE).
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 Nm (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. DO NOT over tighten.

5. Install high pressure injection lines (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL LINES - INSTALLATION).
6. Reconnect injector electrical connectors.
7. Connect negative battery cable.

NOTE:Fuel Injectors have different flow rates. When injectors are removed, re-enter all injector six digit codes.

8. Program all injector codes into the ECM using the scan tool.
9. Start engine, allow to run, turn engine off and inspect for leaks (Refer to FUEL SYSTEM - WARNING).

CAUTION: Care must be taken when installing the engine cover. Assure the proper routing of the fuel injector return fuel hose to the banjo bolt fitting in the left rear corner of the cover. Failure to do so may pinch or damage the hose causing fuel leakage or a driveability concern.

10. Install engine cover (Refer to ENGINE - INSTALLATION).