REMOVAL & INSTALLATION
See Figures 1, 2 and 3
- Remove the injection lines as previously described.
- Disconnect the fuel return hose.
- Remove the nut which holds the fuel return pipe to each injector. Use a second wrench to counterhold the injector.
- Remove the fuel return pipe from the injectors.
- Use a long, deep socket to remove each injector from the head. After the injectors are out, remove the gasket from each nozzle hole.
- When reinstalling, clean the nozzle holder mounting area of the cylinder head.
- Install a new nozzle tip gasket and a new nozzle holder gasket into the cylinder head. New gaskets are required to prevent high pressure fuel leaks.
- Install the injectors into the head and tighten each to 41 ft. lbs. (55 Nm).
- Install the return pipe gaskets onto the injector nozzles and install the fuel return pipe onto the injectors.
- Use two wrenches to counterhold and tighten the return line retaining nuts. Tighten them to 26 ft. lbs. (35 Nm).
- Install the fuel return hose.
- Install the fuel supply lines.
There is no way to test diesel fuel injectors without an elaborate test bench. Your dealer or service center may have this equipment. Do not attempt to test the injector by connecting it to the fuel line while out of the engine. You'll bend the line and run the risk of injury. The injector releases fuel under a pressure of 1707 psi (11,761 kPa) or higher; this is more than enough pressure to force atomized fuel through your skin and induce blood poisoning.
Once the injector is set up on a proper test bench, it should be checked for spray pattern, noise, break pressure and leakage. Each one of these characteristics must be within specification or the injector must be replaced.