Preparatory Steps:
• Clean around the injectors.
• Disconnect the high pressure fuel supply lines.
• Disconnect the fuel drain manifold.
Rust Penetrating Solvent
Caution: When rust has formed on the hold down nut, the injector can turn in the bore when the nut is loosened. This will cause severe damage to the head by the injector locating ball cutting a groove in the bore.
Soak the hold down nut with a rust penetrating solvent for a minimum of 3 minutes.
24 mm Box Wrench, Adjustable Wrench
Hold the injector body with an adjustable wrench while you loosen the hold down nut with a 24 mm box wrench.
Injector Puller 3823276
Remove the injectors. An injector puller is available for difficult to remove injectors.
It may be necessary to tap the injector with the injector puller to work the injector up and down in order to remove it.
Injector Bore Brush 3822509
Clean the injector nozzle bore.
Assemble the injector and new copper sealing washer.
Use only one copper washer.
Service Tip: A light coat of clean 15W40 engine oil between the washer and injector can help to keep the washer
from falling during installation.
Warning: Early model injectors (pre 1991) have a 9 mm injector tip which cannot be used in engines built in 1991
or later as these engines use a 7 mm injector tip.
7 mm injectors can be used in early model (9 mm) injector holes providing the special adapter sleeve is installed
onto the 7 mm injector tip.
Apply a coat of anti-seize compound to the threads of the injector hold down nut and between the top of the nut and
injector body.
24 mm Deep Well Socket
Caution: Align the Injector’s protrusion with the notch in the bore.
Torque Value: 80 N»m [44ft-IbJ
NOTE: The current Bosch injector has an o-ring located above the hold down nut. After tightening the injector be sure
to push the o-ring into the groove.
Assemble the fuel drain manifold and high pressure lines.
Leave the high pressure fittings loose at the injectors.
17 mm, 19 mm
Caution: It is necessary to put the engine in the “ run” position. Because the engine may start, be sure to follow
all the safety precautions. Use the normal engine starting procedure.
Crank the engine to allow entrapped air to bleed from the lines. Tighten the fittings.
