INSTALLATION

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.

NOTE: Apply anti-seize compound to injector body (1).

1. Install fuel injector into cylinder head with new seal and O-ring.

2. Install fuel injector retainer clamp (1), washer (3) and bolt (2). Tighten clamp bolt (2) to 33 Nm (24 ft. lbs.) torque.
3. Connect electrical connector to fuel injector.
4. Install fuel injector high-pressure lines. Refer to Fuel Line 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.