Fuel Injector - Removal
REMOVAL
Special Tools:
CAUTION: Refer to Cleaning Fuel System Parts.
NOTE: Six individual, solenoid actuated high-pressure fuel injectors are used. The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors, mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line.
NOTE: Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Powertrain Control Module (PCM) using a scan tool. In addition, if a new PCM is installed, use a scan tool to program all six of the injector codes from the original fuel injectors into the new PCM.
NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code.
1. Disconnect both negative battery cables.
2. Remove engine cover.
3. Remove breather assembly and tubes.
4. Remove cylinder head cover Cylinder Head Cover(s) - Removal
NOTE: Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector and is used to identify injector calibration.
5. Mark each injector (2) with its corresponding cylinder number. If required, make note of each fuel injector six-digit alphanumeric correction code (1).
6. Remove all 12 fuel injector wire harness nuts (1) securing integrated wiring harness to all 6 fuel injectors.
7. Disconnect both fuel injector harness connectors (3) and remove the integrated gasket.
8. Remove the high pressure fuel tubesFuel Tube(s) - Removal
9. Remove connector retainer nuts (12).
10. Install the High Pressure Connector Remover (4) onto high-pressure connector tube located in cylinder head.
11. Using Thread High Pressure Connector Remover (2), pry and remove the high-pressure connector tube(s) (4) from the cylinder head.
12. Remove fuel injector hold-down clamp bolts (1)
13. Remove necessary intake and exhaust rocker arm assembly(s).
NOTE: The rocker housing support bridge is bolted to the top of cylinder head. The mounting stud from Fuel Injector Removal/Installer was meant to temporarily replace a rocker housing mounting bolt.
14. Remove the necessary rocker housing mounting bolt.
CAUTION: Fuel Injector Removal/Installer is equipped with 2 clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a 2-piece mounting stud and a pivoting handle. Do not attempt to remove the fuel injectors with any other device. Damage to injector will occur.
15. Install and tighten 2-piece mounting stud (3) of Fuel Injector Removal/Installer , to rocker housing (4). If removing the No. 6 fuel injector, separate the 2-piece mounting stud (3). Install lower half of mounting stud (3) to center of rocker housing bridge (4) and upper half of mounting stud to lower half.
16. Position tool handle (2) to mounting stud (3) and install handle nut (1). Leave handle nut (1) loose to allow a pivoting action.
17. Position lower part of clamshell halves (5) to sides of fuel injector (6) (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles (2) pivoting head.
18. Slide the retainer sleeve (7) over pivoting handle head (2) to lock clamshell halves (5) together. Be sure handle pivot nut (1) is loose.
19. Depress handle of Fuel Injector Removal/Installer (2) downward to remove fuel injector straight up from cylinder head bore.
NOTE: If the fuel injectors are being removed such as for engine teardown or diagnostic purposes, be sure to mark each injector with its corresponding cylinder number. The fuel injectors MUST be reinstalled into the original (same) cylinder due to the fuel injector correction code.
20. Remove and discard injector sealing washer (2). This washer should be located on tip of injector (1), or may have remained in the injector bore.
NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded.
21. Measure injector sealing washer (1).