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Fuel Injector: Service and Repair




Fuel Injectors









RH Fuel Injectors

NOTE: RH fuel injectors shown, LH similar.









Fuel Injector Replacement Label









Removal

WARNING: Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

1. WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

Release the fuel system pressure. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Fuel System Pressure Release.

2. Disconnect the battery ground cables. For additional information, refer to Battery, Mounting and Cables Battery Disconnect / Connect.

3. Remove the RH or LH fender splash shield. For additional information, refer to Front End Body Panels Fender Splash Shield.

4. NOTE: The glow plug module must be removed if the RH fuel injectors are being removed.

If necessary, remove the glow plug module. For additional information, refer to Glow Plug System - 6.7L Diesel [1][2]Exploded Views.

5. NOTE: It may be necessary to unthread the engine sound shield retainers from the engine.

Remove the 5 RH or 5 LH engine sound shield retainers and the RH or LH engine sound shield.

6. Disconnect the fuel injector electrical connector.

7. Disconnect the 3 fuel charging wiring harness retainers from the fuel rail.
- Position aside the fuel injector wiring harness.

8. Push down on the tabs and pull up on the center of the fuel injector return hose fitting to unlock the fitting.
- Disconnect the fuel injector return hose fitting from the fuel injector.





9. NOTE: The fuel pressure control valve electrical connector must be disconnected to remove the cylinder No. 8 fuel injector.

If necessary, disconnect the fuel pressure control valve electrical connector.

10. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components.

NOTE: The fuel injector supply tube cannot be reused.

Remove and discard the fuel injector supply tube.

11. NOTE: The fuel injector hold-down clamp bolts are torque-to-yield and cannot be reused.

Remove and discard the fuel injector hold-down clamp bolt.

- Remove the fuel injector hold-down clamp.

12. Install the Injector Removal Tool.

1. Install the Injector Removal Tool to the fuel injector and fully hand-tighten the Injector Removal Tool mounting bolt.

2. Install the allen-head push bolt and tighten to remove the fuel injector.

3. Remove the Injector Removal Tool mounting bolt and the lower portion of the Injector Removal Tool.

4. Remove and discard the O-ring seal and the copper combustion gasket from the fuel injector.

5. Remove and discard the fuel injector return fuel O-ring.





13. NOTE: The PCM is programmed with an IQA code for each fuel injector. Note the fuel injector cylinder location.

Install the fuel injector into the Fuel Injector Cup and store the fuel injector in the corresponding cylinder location in the Fuel Injector Holding Rack.

Installation

1. Install a new fuel injector body O-ring seal and a new copper combustion gasket onto the fuel injector.
- Install a new fuel injector return fuel O-ring.

2. NOTE: If a fuel injector is being reused, make sure to install it in the original location.

Install the fuel injector, the fuel injector hold-down clamp and a new fuel injector hold-down clamp bolt.

1. Lubricate the fuel injector hold-down clamp bolt mating surface of the fuel injector hold-down clamp with clean engine oil.

2. Tighten the fuel injector hold-down clamp bolt to 30 Nm (22 lb-ft).

3. Tighten the fuel injector hold-down clamp bolt an additional 90°.

3. NOTE: If more than one fuel injector supply tube has been removed from either cylinder head, the 2 fuel rail mounting bolts must be loosened before the new fuel injector supply tubes are installed.

If necessary, loosen the 2 fuel rail mounting bolts.

4. NOTE: Use a deep-well crowfoot socket to tighten the fuel injector supply tube.

Install the new fuel injector supply tube in the following sequence.

1. Position the new fuel injector supply tube between the fuel rail and the fuel injector. Fully hand-start and seat the fuel injector supply tube fittings onto the fuel rail and the fuel injector high-pressure connectors.

2. If necessary, tighten the 2 fuel rail mounting bolts.
- Tighten to 24 Nm (18 lb-ft).

3. Pre-tighten the fuel injector supply tube fittings.
- Tighten the fuel injector fitting to 20 Nm (177 lb-in).

- Tighten the fuel rail fitting to 20 Nm (177 lb-in).

4. Final-tighten the fuel injector supply tube fittings.
- Tighten the fuel injector fitting to 35 Nm (26 lb-ft).

- Tighten the fuel rail fitting to 35 Nm (26 lb-ft).

5. If necessary, connect the fuel pressure control valve electrical connector.

6. Connect the fuel injector return hose fitting to the fuel injector.
- Push down on the center of the fuel injector return hose fitting to lock the fitting.





7. Connect the 3 fuel injector wiring harness retainers to the fuel rail.

8. Connect the fuel injector electrical connector.

9. Position the RH or LH engine sound shield and install the 5 RH or LH engine sound shield retainers.

10. If necessary, install the glow plug module. For additional information, refer to Glow Plug System - 6.7L Diesel [1][2]Exploded Views.

11. Install the RH or LH fender splash shield. For additional information, refer to Front End Body Panels Fender Splash Shield.

12. Connect the battery ground cable(s). For additional information, refer to Battery, Mounting and Cables Battery Disconnect / Connect.

13. NOTE: A fuel injector replacement label must be installed for each fuel injector that was replaced.

Install the fuel injector replacement label to the top of the oil separator housing and circle the cylinder number for the fuel injector that has been replaced.

14. NOTE: The PCM must be programmed with the proper fuel injector IQA codes.

Using the scan tool, program the PCM with the appropriate fuel injector IQA code for any fuel injector that was replaced. For additional information, refer to Computers and Control Systems.

15. Prime the fuel system by cycling the ignition 3 times as follows:

1. Turn the ignition key ON without cranking the engine.

2. Wait 30 seconds for the fuel conditioning module to run.

3. Turn the ignition key OFF.

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