Removal
REMOVAL
FUEL INJECTOR ID CORRECTION CODES:
Each fuel injector has a six-digit alphanumeric correction code. The correction code is printed on the intake side of the fuel injector (1) and is used to identify injector calibration. When replacing any fuel injectors, this code must be entered into the vehicles Engine Control Module (ECM) using a diagnostic scan tool. In addition, if a new ECM is installed, use a diagnostic scan tool to program all six of the injector codes from the original fuel injectors into the new ECM.
The valve cover and valve cover gasket will need to be removed in order to manually record the values from the original injectors. Contact cleaner or brake cleaner may be used to clean the fuel injector.
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.
NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded.
CAUTION: Refer to Cleaning Fuel System Parts.
Six individual, solenoid actuated high-pressure fuel injectors (7) 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.
1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.
2. Remove vanity cover.
3. Remove breather assembly and tubes.
4. Remove valve cover.
5. Remove all 12 fuel injector wire harness nuts (1) securing integrated wiring harness to all 6 fuel injectors.
6. An integrated fuel injector wire harness / valve cover gasket (2) is used. After all 12 nuts (1) have been removed, remove this integrated gasket. Before removing gasket, disconnect engine wiring harness at both electrical connectors (3).
7. Remove necessary high pressure fuel line connecting the necessary fuel injector rail to high pressure connector.
8. A connector retainer (nut) is used on each connector tube (12). Remove this nut(s) by unthreading from cylinder head. These nuts (12) hold the fuel injector retainers (13) to the fuel injector.
9. Using special high-pressure connector removal tool #9015 (4) remove necessary high-pressure connector(s) from cylinder head. Tool #9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder head.
10. Remove 2 fuel injector hold-down clamp bolts (1) at each injector being removed.
11. Remove necessary exhaust rocker arm assembly(s).
12. USING TOOL #9010:
a. Special Tool #9010 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 injector with any other device. Damage to injector will occur.
b. The rocker housing is bolted to the top of cylinder head. The mounting stud from tool #9010 was meant to temporarily replace a rocker housing mounting bolt. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 5 rocker housing support bridges.
c. Install and tighten 2-piece mounting stud to rocker housing. If removing the No. 6 fuel injector, separate the 2-piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper half of mounting stud to lower half.
d. Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting action.
e. Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles pivoting head.
f. Slide the retainer sleeve over pivoting handle head to lock clamshell halves together.
g. Be sure handle pivot nut is loose.
h. Depress handle downward to remove fuel injector straight up from cylinder head bore.
13. Remove and discard injector sealing washer (2). This washer (2) should be located on tip of injector, or may have remained in the injector bore.
14. Measure sealing gasket (washer) (1).
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.
NOTE: Do not install new fuel injectors unless the alphanumeric codes have been recorded.