INJECTOR CLASSIFICATION PROCEDURE
(1) Turn ignition switch “ON”.
(2) Usin g a DRB III! a nd select ENGINE then
MISCELLANEOUS.
(3) Select LEARN INJ ECTORS.
(4) Usin g the up an d down arr ows, scroll to th e
appropriate injector.
(5) Usin g t he right a nd left ar rows, set injector to
pr oper classification.
(6) Once in ject ors a re classified, cycle ign ition to
complet e.
CLEANING FUEL INJECTORS
NOTE: Before cleaning the injector recesses, seal
the injector holes in the injector recesses with the
appropriate pin to prevent debris from falling into
the recesses and entering the motor.
(1) Seal the in jector holes inside the cylinder head
recesses.
(2) Wipe ou t in ject or recesses with a non -woven
cloth, then clean with a cylinder br ush.
(3) Clean the bot tom of the cylinder recess with a
round br ush.
(4) Blow out t he r ecess an d clea n again with a
non-woven clot h and cover over.
(5) Perfor m these steps for ea ch injector r ecess.
NOTE: DO NOT clean the tip of the injector with a
wire brush. Use a non - woven cloth.
(6) Clean injector body with a wire brush.
(7) Clean injector tips wit h a non-woven cloth .
NOTE: Do Not apply antiseize lubricant to the injec-
tor nozzle area.
(8) Grease injector body wit h anti seize lu brica nt.
NOTE: Always replace the seals that seal off the
injectors at the cylinder head to the combustion
chamber and replace the retaining screws.
REMOVAL
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
NOTE: When removing injectors, the seal rings and
retaining stretch bolts must always be replaced.
Coat the injector body with the anti-seize com-
pound before installing. Keep lubricant away from
the injector nozzle.
(1) Disconn ect nega tive battery cable.
(2) Remove engine cover (Refer to9-ENGINE-
REMOVAL).
(3) Remove th e fuel retur n hose locking clamps at
the injector a nd remove return hose.
(4) Disconn ect the injector elect rical connector
(Fig. 13).
NOTE: Counterhold injection lines with wrench
socket at threaded connections of injectors.
(5) Disconn ect fuel injector high pressure line (F ig.
13).
(6) Remove fuel in ject or ret aining bolt and tension
claw, then remove th e inject or and seal (Fig. 13).
NOTE: If injectors are tight, remove with extraction
claw in place of tensioning claw. If extraction claw
contacts cylinder head cover, remove cylinder head
cover. If necessary, remove injectors with threaded
adaptor and discard injector.
(7) Remove injectors (Fig. 13).
(8) Clean injectors and recesses (Refer t o 14 -
FUE L SYSTEM/F UEL INJ ECTION/FUEL INJ EC-
TOR - STANDARD P ROCEDURE).
Fig. 13 FUEL INJECTOR REMOVAL / INSTALLATION
1 - FUEL INJECTOR RETURN LINE
2 - RETAINING CLIP
3 - INJECTOR HIGH PRESSURE LINE
4 - INJECTOR SEAL
5 - FUEL INJECTOR
6 - TENSIONING CLAW
7 - SPECIAL TOOLS #8938 AND # 8937
14 - 38 FUEL INJECTION VA
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