Injector Removal and Installation
Special Tools Required
Image Description/Tool Number
9576256.png Pick Up Tool 070AC-5A0A100
9507995.png Injector Seal Installer Kit 070AG-5A0A100

Flammable - Keep Fire Away

NOTE:
Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line.
When replacing the injector, you must replace all injectors on the fuel rail as a set and the fuel joint pipe.
Failure to do so will cause poor engine performance and fuel leaks.


NOTE:
Do not disconnect the water bypass hoses.
Do not bend the water bypass hoses excessively.

3. Intake Manifold Bracket - Remove

5. High Pressure Fuel Pump Cover - Remove

2.
Remove the high pressure fuel pump cover (B).

7. Fuel Rail and Injector - Remove
1.
Remove the bracket (A).
2.
Disconnect the connectors (B).
3.
Remove the fuel rail mounting bolts (C) and nuts (D).
4.
Carefully remove the fuel rail (E) with the injectors straight from the cylinder head.
NOTE:
If the injector remains on the cylinder head, carefully remove the injector straight from the cylinder head.
Note the cylinder number of the injector, and install it to the same cylinder when reinstalling.
If you replace the injector, the fuel rail, or the cylinder head, use a new injector clip (F).

8. Injector - Remove
1.
Remove the injectors (A) from the fuel rail.
2.
Remove the injector clip (B), the O-ring (C), and the back-up ring (D) from the injector.
NOTE: If you replace the injector, the fuel rail, or the cylinder head, use a new injector clip, O-ring, and back-up ring.
3.
Using the pick up tool (A), carefully remove the seal (B) from the injector.


Flammable - Keep Fire Away

NOTE:
Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line.
When replacing the injector, you must replace all injectors on the fuel rail as a set.

1. Injector Seal - Install
NOTE:
Do not wipe off the tip area (A) of the injector as it may be damaged.
If the tip of the injector is dirty or clogged, it must be replaced. The injectors cannot be cleaned.
1.
Use compressed air to insure that there are no dust or debris around the ring (B).
2.
With a paper towel, carefully wipe off any carbon from the area (C) shown.
3.
Quickly push a new seal (A) down to the groove (B) of the injector using the seal guide tool (C) and the seal installer (D).
4.
Joint the sizing tools (A), then slide them as a set onto the seal (B) until tools touch to the injector stepped surface (C) as shown, and hold the tools to reform the seal for 30 seconds or more.
5.
Remove the sizing tool, and check that the seal is installed correctly.
NOTE: When cleaning the sizing tool, be careful not to scratch the sizing tool bore.

2. Injector - Install
1.
Install a new back-up ring (A) and a new O-ring (B) on the injector (C).
NOTE:
Set the direction of the back-up ring as shown
Check that the back-up ring sets correctly after installation.
2.
Coat the O-ring with clean engine oil, then install the injector onto the fuel rail (D) with a new clip (E).
NOTE: When installing the injector, be sure to protect the injector from dust or debris.

3. Fuel Rail and Fuel Injector - Install
1.
Coat the injector holes (A) on the cylinder head with clean engine oil.
2.
Carefully install the fuel rail (B) with the injectors into the cylinder head straight and equal.
NOTE: When installing the injector, protect the tip of the injector from dust or debris.

3.
Install the nuts (C), and tighten slowly in an alternate pattern until the fuel rail sits on the cylinder head.
4.
Tighten the nuts and the bolts (D) to the specified torque.
5.
Connect the connectors (E).
6.
Install the bracket (F).


NOTE: Failure to install a new fuel joint pipe will cause fuel leaks.

5. High Pressure Fuel Pump Cover - Install
1.
Install the high pressure fuel pump cover (A).
NOTE: The cover will be reinstalled after the fuel leak check.