Injectors

REMOVAL & INSTALLATION

1. Remove the injection lines as previously described.
2. Disconnect the fuel return hose.
3. Remove the nut which holds the fuel return pipe to each injector. Use a second wrench to counterhold the injector.
4. Remove the fuel return pipe from the injectors.
5. Use a long, deep socket to remove each injector from the head. After the injectors are out, remove the gasket from each nozzle hole.
6. When reinstalling, clean the nozzle holder mounting area of the cylinder head.
7. Install a new nozzle tip gasket and a new nozzle holder gasket into the cylinder head. New gaskets are required to prevent high pressure fuel leaks.

   Fig. 1: Injection nozzle and fuel return pipes — 2.3L diesel engines

   Fig. 2: A deep socket will be needed to remove the fuel injectors — 2.3L diesel engines

   Fig. 3: Checking the nozzle tip — 2.3L diesel engines

8. Install the injectors into the head and tighten each to 41 ft. lbs. (55 Nm).
9. Install the return pipe gaskets onto the injector nozzles and install the fuel return pipe onto the injectors.
10. Use two wrenches to counterhold and tighten the return line retaining nuts. Tighten them to 26 ft. lbs. (35 Nm).
11. Install the fuel return hose.
12. Install the fuel supply lines.