High Pressure Diesel Fuel Injector Replacement
Single Use Fasteners and Components
  • Exhaust Gas Recirculation Cooler Inlet Pipe Gasket
  • Exhaust Gas Recirculation Pipe Seal
  • Fuel Injector Bolt
  • High Pressure Diesel Fuel Feed to Injector Pipe
  • Injector Fuel Label

Warning: Refer to Diesel/Gasoline Vapors Warning.

Warning: Refer to Safety Glasses Warning.

Special Tools
  • EN-45059-A Angle Meter
  • EN-47909 Injector Bore and Sleeve Cleaning Kit
  • EN-51146-1-3 Sliding Hammer
  • EN-52451 Fuel Injector Remover

Equivalent regional tools:Special Tools

Removal Procedure
  1. Turn OFF the engine for 30 seconds before proceeding. This will purge the fuel pressure from the complete fuel system.
  2. Plenum Front Panel Outer Reinforcement»Remove—Plenum Front Panel Outer Reinforcement Removal and Installation

    3. Object ID: 5171779
  3. Remove the oil filler cap.
  4. Intake Manifold Cover Bolt(1)»Remove
  5. Intake Manifold Cover(2)»Remove
  6. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.

    7. Object ID: 5150211
  7. Air Cleaner Outlet Front Duct Clamp(1)»Loosen[2x]
  8. Air Cleaner Outlet Front Duct(2)»Remove

    9. Object ID: 5150241
  9. Air Cleaner Outlet Duct Clamp(1)»Loosen
  10. Air Cleaner Outlet Duct(2)»Remove

    11. Object ID: 5170071
  11. Remove the 3 engine wiring harness bracket nuts (1).
  12. Position the rear engine wiring harness channel (2) out of the way.

    13. Object ID: 5193255
  13. Engine Coolant Outlet Pipe Bracket Bolt(1)»Remove

    14. Object ID: 5204431

    Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

  14. Remove the 2 exhaust gas recirculation cooler bolts (1).

    15. Object ID: 5206053
  15. Turbocharger Coolant Feed and Return Pipe Bolt(3)»Remove

    16. Object ID: 5204427
  16. Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
  17. Remove the exhaust gas recirculation pipe bolt (2).

    18. Object ID: 5204428
  18. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Remove[2x]

    19. Object ID: 5628860
  19. Exhaust Gas Recirculation Pipe(1)»Remove
  20. Exhaust Gas Recirculation Pipe Seal(2)»Remove and DISCARD
  21. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket(3)»Remove and DISCARD

    22. Object ID: 5624867
  22. Electrical Connector(1)@Nitrogen Oxides Sensor»Disconnect
  23. Wiring Harness Retainer(2)@Charge Air Cooler»Remove[3x]
  24. Electrical Connector(3)@Charge Air Cooler»Disconnect[2x]
  25. Engine Wiring Harness(4)»Position aside

    26. Object ID: 5216906
  26. Wiring Harness Retainer(4)@Charge Air Cooler»Remove

    27. Object ID: 5211335
  27. Charge Air Cooler Outlet Air Hose Clamp (1)»Loosen until disengaged[2x]
  28. Charge Air Cooler Outlet Air Hose(2)»Remove

    29. Object ID: 5211389
  29. Charge Air Cooler Inlet Air Hose Clamp(1)»Loosen until disengaged[2x]
  30. Charge Air Cooler Inlet Air Hose(2)»Remove

    31. Object ID: 5217133
  31. Charge Air Cooler Bolt(1)»Remove[4x]

    32. Object ID: 5217156
  32. Reposition the charge air cooler (1) with coolant hoses attached.

    33. Object ID: 5812589

    Note: The injector fuel label located on the engine charge air cooler will become invalid and MUST be removed and DISCARDED if ANY fuel injector is replaced. The label is only accurate as long as the original fuel injectors are installed.

  33. Remove and DISCARD the injector fuel label (1).

    34. Object ID: 5187895
  34. Upper Intake Manifold Brace Nut(1)»Remove[3x]
  35. Reposition the upper intake manifold bracket (2) with the nitrogen oxides sensor.

    36. Object ID: 5185361
  36. Turbocharger Heat Shield Bolt(1)»Remove[2x]
  37. Turbocharger Heat Shield Nut(2)»Remove

    38. Object ID: 5185371
  38. Reposition the turbocharger heat shield (1) with the exhaust gas recirculation temperature sensor attached.

    39. Object ID: 5219691
  39. Release the retaining spring (1).
  40. Intake Manifold Resonator(2)»Remove

    41. Object ID: 5138644
  41. Turbocharger Bracket Bolt(1)»Remove

    42. Object ID: 5499646
  42. Engine Wiring Harness Bracket Nut(1)»Remove[2x]
  43. Engine Wiring Harness Bracket(3)»Reposition

    44. Object ID: 5217555
  44. Oil Filler Tube Support Stud(1)»Remove

    45. Object ID: 5499644
  45. Engine Coolant Air Bleed Hose Clip(1)»Remove

    46. Object ID: 5217574
  46. Charge Air Cooler Bolt(1)»Remove[5x]
  47. Charge Air Cooler Bracket(2)»Remove

    48. Object ID: 5149255
  48. Reposition harness, hoses, and connect electrical connectors as needed.
  49. Exhaust Gas Recirculation Pipe Bracket Bolt(1)»Remove
  50. Exhaust Gas Recirculation Pipe Bracket(5)»Remove

    51. Object ID: 5135087

    Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

  51. Camshaft Housing Cover Insulator(1)»Remove

    52. Object ID: 5158567
  52. Loosen the high pressure diesel fuel feed pipe nuts (1) from the fuel injector and the fuel injection rail, as needed.

    53. Object ID: 5630549
  53. Remove and DISCARD the high pressure diesel fuel feed to injector pipe(s), as needed (2).

    54. Object ID: 5159300

    Note: Only replace the faulty injector.

  54. Disconnect the high pressure diesel fuel injector electrical connectors (1), as needed.
  55. Disconnect the fuel injector wiring harness retainers (2), as needed and reposition the fuel injector wiring harness out of the way.

    56. Object ID: 5621181
  56. Disengage the fuel return hose connector (4), as needed.

    57. Object ID: 5621182
  57. Fuel Injection Fuel Return Pipe(1)»Reposition

    58. Object ID: 5136920
  58. Fuel Injector Bolt(1)»Remove and DISCARD
  59. Multiport Fuel Injector Bracket(2)»Remove

    60. Object ID: 5136921

    Note: The EN-52451 Fuel Injector Remover and EN-51146-1-3 Sliding Hammer are only used for high pressure diesel fuel injectors 1, 2, 3, or 4.

  60. Remove the faulty high pressure diesel fuel injector (2) using the EN-52451 Fuel Injector Remover (3) and EN-51146-1-3 Sliding Hammer (1).

    61. Note: The EN-51146-1-3 Sliding Hammer cannot be used to remove high pressure diesel fuel injectors 5 or 6.

  61. Remove the faulty high pressure diesel fuel injector (2) using the EN-52451 Fuel Injector Remover (3) and a suitable tool, to rotate the high pressure diesel fuel injector left and right in its bore until it is released from its seat.

    62. Object ID: 5136923
  62. Remove the faulty high pressure diesel fuel injector (1).
  63. Using the EN-47909 Injector Bore and Sleeve Cleaning Kit, clean the high pressure diesel fuel injector bores as needed.
Cleaning and Inspection Procedure - Required

    Object ID: 5854827
  1. Inspect the charge air cooler inlet air hose (2):
    1. Use dish soap and water to clean the inside of the charge air cooler inlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces.
    2. Inspect the interior of the charge air cooler inlet air hose (2) for tears or delamination. Replace the hose if damage is found.
    3. Inspect the charge air cooler inlet air hose clamps (1). Replace the charge air cooler inlet air hose (2) if damage is found or the clamp components are missing.

    Object ID: 5854825
  2. Inspect the charge air cooler outlet air hose (2):
    1. Use dish soap and water to clean the inside of the charge air cooler outlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces.
    2. Inspect the interior of the charge air cooler outlet air hose (2) for tears or delamination. Replace the hose if damage is found.
    3. Inspect the charge air cooler outlet air hose clamps (1). Replace the charge air cooler outlet air hose (2) if damage is found or the clamp components are missing.
Cleaning and Inspection Procedure - Conditional

Note: The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation.


    Object ID: 5145897

    Caution: The fuel injector must be cleaned with the proper cleaning equipment. DO NOT use abrasive cleaning methods, such as a metallic brush, to remove deposits. Cleaning an injector with improper tools will damage the fuel injector.

  1. Using a soft bristle non-metallic brush and top engine cleaner, remove any deposits from the high pressure diesel fuel injector nozzle tip (1) and the copper washer sealing area before installation.
  2. Inspect the high pressure diesel fuel injector nozzle tip (1) for cracks, dents, or other damage.
  3. Inspect the high pressure diesel fuel injector nozzle tip (1) for any signs of discoloration.
Installation Procedure
  1. Record the Injector Flow Identifier Information from the new injector(s).
  2. Apply a small amount of dielectric grease to the high pressure diesel fuel injector electrical connector. Adhesives, Fluids, Lubricants, and Sealers

    3. Object ID: 5136923
  3. Install the NEW high pressure diesel fuel injector (1) to the cylinder head.

    4. Object ID: 5136920

    Note: Note the mounting position of the injector bracket.

  4. Multiport Fuel Injector Bracket(2)»Install

    5. Note: Do NOT tighten the fuel injector bolt until after the high pressure diesel fuel feed pipes are installed.

  5. Fuel Injector Bolt(1)»Install NEW

    6. Object ID: 5621182
  6. Fuel Injection Fuel Return Pipe(1)»Install

    7. Object ID: 5621181
  7. Engage the fuel return hose connector (4), as needed.

    8. Object ID: 5159300
  8. Install the fuel injector wiring harness and connect the fuel injector wiring harness retainers (2), as needed.
  9. Connect the high pressure diesel fuel injector electrical connectors (1), as needed.

    10. Object ID: 5630549
  10. Install NEW high pressure diesel fuel feed to injector pipe(s) (2), as needed.
  11. Hand tighten the high pressure diesel fuel feed to injector pipe fittings (1), as needed.

    12. Caution: Refer to Component Fastener Tightening Caution.

  12. Tighten the high pressure diesel fuel feed to injector pipe fittings (1), as needed. Fastener Specifications

    13. Object ID: 5136920

    Note: Tighten the fuel injector bolt only after installing the high pressure diesel fuel feed pipes.

    Caution: Refer to Fastener Caution.

  13. Using the EN-45059-A Angle Meter, tighten the NEW fuel injector bolt (1). Fastener Specifications

    14. Object ID: 5135087

    Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

    Note: Ensure the camshaft housing cover insulator is properly seated.

  14. Camshaft Housing Cover Insulator(1)»Install

    15. Object ID: 5149255
  15. Exhaust Gas Recirculation Pipe Bracket(5)»Install
  16. Exhaust Gas Recirculation Pipe Bracket Bolt(1)»Install and tighten—Fastener Specifications
  17. Reposition harness, hoses, and connect electrical connectors as needed.

    18. Object ID: 5217574
  18. Charge Air Cooler Bracket(2)»Install

    19. Caution: Refer to Fastener Caution.

  19. Charge Air Cooler Bolt(1)»Install and tighten[5x]—Fastener Specifications

    20. Object ID: 5499644
  20. Engine Coolant Air Bleed Hose Clip(1)»Install

    21. Object ID: 5217555
  21. Oil Filler Tube Support Stud(1)»Install—Fastener Specifications

    22. Object ID: 5499646
  22. Engine Wiring Harness Bracket»(3)Install
  23. Engine Wiring Harness Bracket Nut(1)»Install and tighten[2x]—Fastener Specifications

    24. Object ID: 5138644
  24. Turbocharger Bracket Bolt(1)»Install and tighten—Fastener Specifications

    25. Object ID: 5219691
  25. Intake Manifold Resonator(2)»Install
  26. Engage the retaining spring (1).

    27. Object ID: 5185371
  27. Turbocharger Heat Shield(1)»Install

    28. Object ID: 5185361
  28. Turbocharger Heat Shield Nut(2)»Install and tighten—Fastener Specifications
  29. Turbocharger Heat Shield Bolt(1)»Install and tighten[2x]—Fastener Specifications

    30. Object ID: 5187895
  30. Install the upper intake manifold bracket (2) with nitrogen oxides sensor attached.
  31. Upper Intake Manifold Brace Nut(1)»Install and tighten[3x]—Fastener Specifications

    32. Object ID: 5217156
  32. Charge Air Cooler(1)»Install

    33. Object ID: 5217133
  33. Charge Air Cooler Bolt(1)»Install[4x]—Fastener Specifications

    34. Object ID: 5211389
  34. Charge Air Cooler Inlet Air Hose(2)»Install
  35. Charge Air Cooler Inlet Air Hose Clamp(1)»Tighten[2x]—Fastener Specifications

    36. Object ID: 5211335
  36. Charge Air Cooler Outlet Air Hose(2)»Install
  37. Charge Air Cooler Outlet Air Hose Clamp(1)»Tighten[2x]—Fastener Specifications

    38. Object ID: 5216906
  38. Wiring Harness Retainer(4)@Charge Air Cooler»Install

    39. Object ID: 5624867
  39. Engine Wiring Harness(4)»Reposition
  40. Wiring Harness Retainer(2)@Charge Air Cooler»Install[3x]
  41. Electrical Connector(3)@Charge Air Cooler»Connect[2x]
  42. Electrical Connector(1)@Nitrogen Oxides Sensor»Connect

    43. Object ID: 5628860
  43. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket(3)»Install NEW
  44. Exhaust Gas Recirculation Pipe Seal(2)»Install NEW
  45. Exhaust Gas Recirculation Pipe(1)»Install

    46. Object ID: 5208251

    Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

  46. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Install and hand tighten[2x]

    47. Object ID: 5204427
  47. Install and hand tighten the exhaust gas recirculation outlet pipe bolt (2).
  48. Install the turbocharger coolant return hose clip (1).

    49. Object ID: 5204431
  49. Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).

    50. Object ID: 5208251

    Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

  50. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Tighten in sequence[2x]—Fastener Specifications

    51. Object ID: 5204427
  51. Exhaust Gas Recirculation Outlet Pipe Bolt(2)»Tighten in sequence[2x]—Fastener Specifications
  52. Install the turbocharger coolant return hose clip (1).

    53. Object ID: 5204431
  53. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Tighten in sequence[2x]—Fastener Specifications

    54. Object ID: 5206053
  54. Install and tighten the turbocharger coolant feed and return pipe bolt (3).Fastener Specifications

    55. Object ID: 5193255
  55. Engine Coolant Outlet Pipe Bracket Bolt(1)»Install and tighten—Fastener Specifications

    56. Object ID: 5170071
  56. Install the rear engine wiring harness channel (2).
  57. Install and tighten the 3 engine wiring harness bracket nuts (1). Fastener Specifications

    58. Object ID: 5150241
  58. Air Cleaner Outlet Duct(2)»Install
  59. Air Cleaner Outlet Duct Clamp(1)»Tighten—Fastener Specifications

    60. Object ID: 5150211
  60. Air Cleaner Outlet Front Duct(2)»Install
  61. Air Cleaner Outlet Duct Clamp(1)»Tighten[2x]—Fastener Specifications

    62. Object ID: 5171779
  62. Oil Filler Cap»Remove
  63. Intake Manifold Cover(2)»Install
  64. Intake Manifold Cover Bolt(1)»Install and tighten—Fastener Specifications
  65. Oil Filler Cap»Install
  66. Plenum Front Panel Outer Reinforcement»Install—Plenum Front Panel Outer Reinforcement Removal and Installation
  67. Prime the fuel system and inspect for leaks. Fuel System Priming
  68. Start the engine and check for exhaust leaks.
  69. Perform the following steps:
    1. High Pressure Fuel Variable Reset High Pressure Fuel Variable Reset
    2. Fuel Injector Flow Rate Programming Fuel Injector Flow Rate Programming