How to Remove a Diesel Fuel Injector

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  • 2-4 hours
  • Advanced
  • 0-100
What You'll Need
Service manual of your automobile
Cleaning material
Wads of tissue or cloth to close openings
Screw driver

A diesel fuel injector is a very important component of the diesel car's engine. The diesel engine, unlike the gasoline engine, injects fuel directly into the cylinder. This exposes it to heat and pressure, which might, overtime, damage the fuel injector or decrease its productivity. Removing a diesel fuel injector is a simple process; however, it does require some basic knowledge of the system. The following are simple step-by-step instructions which should allow you to easily perform this task yourself within an hour or so.

Step 1 - Depressurize and Drain Fuel

As fuel injector is under high pressure and contains high-pressure fuel inside, which can spurt out violently if removed. It is essential that the fuel injector is drained and depressurized properly. Therefore, the first thing that you should do is to ensure that there is no fuel in the fuel pump or rail and that the pressure in the fuel injector has been relieved. The service manual of your automobile should provide you with easy step-by-step guidance to do this successfully.

Step 2 - Make Sure the Engine is Cool

Remember, safety always comes first. Before you begin removing the fuel injectors, make sure that the engine is cool so as to avoid any risk of burn injuries.

Step 3 - Clean Everything

fuel pump

Also, before you begin, make sure that the fuel injection system and all its components are clean. Clean all connections on the fuel system and close any and all open connections since dust and dirt can destroy the entire fuel injection system.

Step 4 - Detach All Fuel Lines

If your engine has a fuel rail, then proceed on to the next step.

If, however, your engine has fuel lines instead of a fuel rail, then remove both the fuel supply and the return lines from the injectors. This ensures disconnection of any fuel supply to the injector. Otherwise, you risk getting fuel sprayed all over you.

Step 5 - Loosen the Fuel Rail

You will now remove the bolts that are attached to the engine's fuel rail in order to be able to move it. After this, gently pry the fuel rail loose using a screwdriver. Take special care while doing this so as not to damage the fuel injectors while loosening the rail. Otherwise, you will need to purchase your entire set of fuel injectors again. The fuel rail should easily come loose after you repeat the same process in three to four different places around the rail.

Step 6 - Loosen the Injector

Once you have cut all fuel delivery to the injector, you are now ready to proceed to remove it. The injector is held in place in a holder that has bolts at its sides. Remove the bolts and take out the holder very carefully so as to avoid damaging anything. Keep the bolts and washers in a safe place.

Step 7 - Remove the Injector

fuel injectors

Using the same wrench, pull out the injector carefully and gently. Remove the rear most injector first. Make sure that the injector is pulled straight out of the bore in relation to the bore's direction, lifting the injector at an angle can wedge the injector inside the bore. Now place the injectors on a suitable surface.

By following these steps, you will have removed the injector.