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. You can get a company out to do mobile injector removals if you get caught short at the side of the road!

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

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 as 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 four 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 now 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.