Fuel Injector

Fuel Injector - Installation5 steps

Install fuel injector(s) (3) into fuel rail assembly (4) and install retaining clip(s) (2).
If same injector(s) is being reinstalled, install new O-ring(s). Two different O-rings are being used. These can be easily identified by color. Install black O-ring at intake manifold end of injector. Install red/rust colored O-ring at fuel rail end of injector.
Apply a small amount of clean engine oil to each injector O-ring. This will aid in installation.
Install fuel rail. Fuel Rail - Installation
Start engine and check for fuel leaks.

Fuel Injector - Removal2 steps

Remove fuel rail. Fuel Rail - Removal
Disconnect clip(s) (2) that retain fuel injector(s) (3) to fuel rail (4) (Figure 1).

Descriptionreference

DESCRIPTION An individual fuel injector (1) (Figure 1) is used for each individual cylinder.

FUEL INJECTORS📷 1

1 - INJECTOR BODY

2 - FUEL OUTLET NOZZLE 3 - FUEL INLET NOZZLE

An individual fuel injector (1) is used for each individual cylinder. See Fig. 87.

FUEL INJECTORS

The top (fuel entry) end of the injector is attached into an opening on the fuel rail. See Fig. 87.

The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber.

The nozzle (outlet) ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector.

The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives.

Battery voltage is supplied to the injectors through the ASD relay.

The PCM determines injector pulse width based on various inputs.

FUEL INJECTORS - PCM OUTPUT

The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with its respective cylinder number.

The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives.

Battery voltage (12 volts +) is supplied to the injectors through the ASD relay. The ASD relay will shut-down the 12 volt power source to the fuel injectors if the PCM senses the ignition is on, but the engine is not running. This occurs after the engine has not been running for approximately 1.8 seconds.

The PCM determines injector on-time (pulse width) based on various inputs.

FUEL INJECTORS📷 1

1 - PLIERS 2 - INJECTOR CLIP 3 - FUEL INJECTOR 4 - FUEL RAIL - TYPICAL

1. Remove fuel rail. See REMOVAL.

2. Disconnect clip(s) (2) that retain fuel injector(s) (3) to fuel rail (4). See Fig. 88.

FUEL INJECTORS📷 1

1 - PLIERS 2 - INJECTOR CLIP 3 - FUEL INJECTOR 4 - FUEL RAIL - TYPICAL

1. Install fuel injector(s) (3) into fuel rail assembly (4) and install retaining clip(s) (2). 2. If same injector(s) is being reinstalled, install new O-ring(s). Two different O-rings are being used. These can be easily identified by color. Install black O-ring at intake manifold end of injector. Install red/rust colored O-ring at fuel rail end of injector. 3. Apply a small amount of clean engine oil to each injector O-ring. This will aid in installation. 4. Install fuel rail. See INSTALLATION. 5. Start engine and check for fuel leaks.

RELAY-FUEL PUMP

FUEL INJECTOR📷 1

To control the injection valves, the new Common-Rail injectors use a rapid-action actuator made of piezo crystals, which opens and closes the injection valve. The piezo crystals expand when electrical current is applied to them, and contract when electrical current is turned off. The piezo actuator can switch up to five times faster than a standard solenoid, because the movement of the piezo crystals does not rely on mechanical components to transmit motion to the injection valve. This doubles the piezo injector's switching speed, and enables fuel to be delivered with greater precision, which leads to lower emissions and better engine performance.

INJECTOR CLASSIFICATION📷 1

Each fuel injector has a alphanumeric correction code number. This correction code is printed on the upper part of the fuel injector (3) 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 of the injector codes from the original fuel injectors into the new ECM.

The classification of injectors describes the fuel flow quantity characteristic of the injector. This will make it possible in the future to match the engine software to the tolerances of the injector within a more narrowly graduated range. Classification can be clearly recognized, and assigned only by means of a scan tool.

These general conditions equally apply if, as a result of replacing an engine, carrying out repairs to the cylinder head etc, the cylinder selective assignment of the injectors or the engine control module assignment may have changed. If proper attention is not paid to the classification on these vehicles, driveability and smoking concerns could result.

If an injector is replaced, it is then necessary to assign the classification code to the corresponding cylinder in the ECM (Engine Control Module) with the appropriate scan tool.

INJECTOR CLASSIFICATION PROCEDURE📷 9

1.   Turn ignition switch "ON".
  2.   Using the diagnostic scan tool, select ENGINE then MISCELLANEOUS.
  3.   Select LEARN INJECTORS.
  4.   Using the up and down arrows, scroll to the appropriate injector.
  5.   Using the right and left arrows, set injector to proper classification code.
  6.   Once injectors are classified, cycle ignition key to complete.

Removal

CAUTION: Due to the complexity of the fuel injection system used on this engine, service any fuel system DTCs prior to replacing any fuel injectors. If no DTCs are present, refer to the appropriate Diesel Engine Diagnostic Test for Lack of Engine Power, and perform all steps as directed prior to replacing any fuel injectors.

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high- pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.

1

Disconnect negative battery cable at battery. Isolate end of cable.

2

Remove dress-up cover from top of engine.

3

Remove the high-pressure fuel lines from fuel rail to fuel injectors. Refer to REMOVAL .

4

Locate common fuel return line (1).

5

Disconnect electrical connector at top of injector(s).

NOTE

The injector common fuel return line is connected to the low pressure fuel circuit (5 bar/72 psi).

6

A lock button (1) is used to secure the common fuel return line to each fuel injector. Use your fingers to

lift all four lock buttons (1) up. After unlocking all four buttons, lift fuel return line assembly up for

Removal

7

Remove injector mounting bolt (2) and washer (3).

8

Remove injector mounting clamp (1).

9

Using compressed air, thoroughly clean surface area in and around injector bore to prevent foreign

material from falling into the injector bore after injector removal.

10

Using your hand, pull fuel injector straight up from cylinder head for removal.

11

If injector can't be removed by hand, install special fuel injector removal tool #9552 (2) to top of fuel

injector.

12

Install special slide hammer tool #8941 (1) onto special tool #9552 (4). Tighten lock nut (2). Remove

injector from cylinder head.

NOTE

DO NOT use a wire brush to clean the fuel injector or nozzle. Possible restriction of the injector needle may result.

Installation

CAUTION: Due to the complexity of the fuel injection system used on this engine, service any fuel system DTCs prior to replacing any fuel injectors. If no DTCs are present, refer to the appropriate Diesel Engine Diagnostic Test for Lack of Engine Power, and perform all steps as directed prior to replacing any fuel injectors.

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high- pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new

parts, lubricate them with clean engine oil or clean diesel fuel only.

NOTE: DO NOT use a brush to clean around the injector nozzle (2). DO NOT lubricate area around injector nozzle. The injector may become restricted with debris.

NOTE: Be sure a new copper washer/seal (3) is installed on end of injector and the old seal is removed, before installing in cylinder head.

1

Install fuel injector into cylinder head with new seal.

2

Install fuel injector retainer clamp (1), washer (3) and bolt (2). Tighten clamp bolt (2) to 33 N.m (24 ft.

lbs.) torque.

3

Connect electrical connector to fuel injector.

4

Install fuel injector high-pressure lines. Refer to INSTALLATION .

5

Position female fittings on fuel return line to male fittings at each fuel injector. Be sure lock buttons (1)

are in up position before positioning.

6

After positioning, push each lock button (1) down to secure fuel return line to each fuel injector.

7

Connect each fuel injector electrical connector.

8

Connect negative battery cable.

9

Perform the injector classification procedure with a diagnostic scan tool.

10

Start the engine and allow to warm. Turn off the ignition switch and inspect for fuel leaks.

11

Install engine dress-up cover.

Parts

Labor

Removal

Removal

Installation