NOTE: Always replace the seals that seal off the
injectors at the cylinder head to the combustion
chamber and replace the retaining screws.
REMOVAL
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 1600BAR (23,200 PSI).
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. FUEL UNDER THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
FOR HIGH-PRESSURE LEAKS WITH A SHEET OF
CARD BOARD. WEAR SAFETY GOGGLES AND
ADEQUATE PROTECTIVE CLOTHING WHEN SER-
VICING FUEL SYSTEM.
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
NOTE: The engine must be lowered in the vehicle to
remove the fourth and fifth cylinders fuel injectors.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Raise and suitably support the vehicle.
(4) Remove lower radiator deflector plate.
(5) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(6) Remove turbocharger down pipe assembly.
(7) Remove oil dipstick tube retaining bolt and pull
tube from oil pan.
(8) Lower vehicle.
(9) Remove upper radiator hose.
(10) Remove air cleaner box assembly and hoses.
(11) Remove charge air cooler inlet hose.
(12) Remove charge air cooler to turbocharger inlet
adaptor.
(13) Remove turbocharger to right engine mount
bracket.
(14) Disconnect steering coupler at gear box (RHD
Only).
(15) Remove battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - REMOVAL).
(16) Unclip PDC from battery tray and set aside.
(17) Remove battery tray (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/TRAY - REMOVAL).
(18) Remove power steering reservoir (Refer to 19 -
STEERING/PUMP/RESERVOIR - REMOVAL).
(19) Remove charger air cooler outlet hose.
(20) Remove intake manifold to left engine mount
bracket.
(21) Evacuate air conditioning system (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE).
(22) Disconnect air conditioning suction / discharge
lines at A/C compressor.
(23) Disconnect pedal position sensor electrical
connector.
(24) Unplug injector electrical connectors.
(25) Remove fuel / water separator to intake man-
ifold retaining bolts.
(26) Support engine with hoist.
(27) Remove engine mount through bolts.
(28) Remove right engine mount sill plate.
NOTE: Counterhold injection lines with wrench
socket at threaded connections of injectors.
(29) Disconnect fuel injector high pressure line.
(30) Remove fuel injector retaining bolt and ten-
sion claw.
(31) Suitably lower engine to gain fuel injector
access and remove injector.
NOTE: If injectors are tight, remove with extraction
claw in place of tensioning claw. If extraction claw
contacts cylinder head cover, remove cylinder head
cover. If necessary, remove injectors with threaded
adaptor and discard injector.
(32) Remove injectors (Fig. 10).
(33) Clean injectors and recesses (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
INSTALLATION
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 1600BAR (23,200 PSI).
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. FUEL UNDER THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
FOR HIGH-PRESSURE LEAKS WITH A SHEET OF
CARD BOARD. WEAR SAFETY GOGGLES AND
ADEQUATE PROTECTIVE CLOTHING WHEN SER-
VICING FUEL SYSTEM.
VA FUEL INJECTION 14 - 23
FUEL INJECTOR (Continued)
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