GM Chevy Mid-Size Cars 1964-1988 Repair Guide

Injection Nozzle

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

Through 1979
  1. Remove the fuel return line from the nozzle.
  2.  
  3. Remove the nozzle hold-down clamp and spacer using tool No. J-26952, or equivalent.
  4.  
  5. Remove the nozzle form the engine, then cap the high pressure line and nozzle tip.
  6.  

The nozzle tip is highly susceptible to damage and must be protected at all times.

To install:
  1. If an old nozzle is to be reinstalled, a new compression seal and carbon stop seal must be installed after removal of the used seals.
  2.  
  3. Remove the caps and install the nozzle, spacer and clamp. Torque to 25 ft. lbs. (34 Nm).
  4.  
  5. Connect return line, then start the engine and check for leaks.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Checking injection nozzle seat tightness



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Fig. Fig. 2: Injection nozzle types



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Fig. Fig. 3: Injection nozzle and glow plug installation

1982-84 Models

After the fuel lines are removed, the injection nozzles on these engines are simply unbolted from the cylinder head in similar fashion to a spark plug. Be careful not to damage the nozzle end and make sure you remove the copper nozzle gasket from the cylinder head if it does not come off with the injection nozzle. Clean the carbon off the tip of the nozzle with a soft brass wire brush and install the nozzles, with gaskets.

1981 and later models use two types of injectors, CAV Lucas or Diesel Equipment. When installing the inlet fittings, torque the Diesel Equipment injector fitting to 45 ft. lbs. (61 Nm) and the CAV Lucas to 25 ft. lbs. (34 Nm).

 
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