Removal Procedure
High Pressure Lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 1600 Bar (23, 200 psi). Use extreme caution when inspecting for high pressure leaks. Fuel under this amount of pressure can penetrate skin causing personal injury, or death. Wear safety goggles and adequate clothing when servicing this fuel system.
The fuel injector label located on the engine front cover will become invalid and MUST be removed and DISCARDED if ANY fuel injector is replaced.
- Turn OFF the engine for 30 seconds before proceeding. This will ensure fuel pressure has purged from the fuel system.
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (Single Battery) , or Battery Negative Cable Disconnection and Connection (Dual Battery)
- Intake Manifold Cover Insulator - Remove - Intake Manifold Cover Insulator Replacement
- Fuel Injection Fuel Feed Pipe - Fuel Injector to Fuel Rail - Remove and DISCARD - Fuel Injection Fuel Feed Pipe Replacement (Fuel Injector to Fuel Rail) , or Fuel Injection Fuel Feed Pipe Replacement (Fuel Pump to Fuel Rail)
- Fuel Injection Fuel Return Pipe - Remove - Fuel Injection Fuel Return Pipe Replacement
Electrical Connector (1) @ Fuel Injector (2) - Disconnect
- NOTE:
- ALWAYS clean ANY debris from around the fuel injectors before removing to prevent contamination.
- ALWAYS mark the original fuel injector locations for correct reinstallation to the same engine cylinders. Failure to do so may result in a poor performance.
Fuel Injector Bracket Bolt (1) - Remove
- Fuel Injector Washer (2) - Remove
Using J-46594 Fuel Injector Puller (1), remove the fuel injector (2) and the fuel injector hold down clamp (3) by using the special tool as a lever lifting them both away from the valve rocker arm cover.
Combustion Fuel Injector Seal (1) - Remove and DISCARD
Only the intake manifold cover insulator replacement - top of engine procedure will need to be completed in order to remove the fuel injectors for cylinders #1, #2, and #3.
High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.