Diagnostics

With the growth of new technologies, such as hybridization and active safety systems, the electronic content will only continue to increase. If independent garages are going to be able to repair these vehicles efficiently, the scope and power of the diagnostics tools and test equipment they use must match the complexity of these systems.

Newsroom

Visit the Newsroom and browse the latest news articles and press releases to find out more about Delphi.

About Us

With a presence in more than 150 countries, and a global network of over 2750 service centres, Delphi aftermarket provides OE specification end-to-end solutions from components to sophisticated software solutions.

Part resource centre how it works header
Resource Center 1 min read

How to remove and replace a diesel common rail injector

Share Resource:
Fuel Systems How to Technicians 1 min read

Resource Highlights

In this article you will find a step-by-step guide on how to remove and replace a diesel common rail injector.

In this video, we'll show you a step-by-step guide on how to remove and replace a common rail diesel injector. Before working on any high-pressure diesel system its good process to make sure that we've no residual pressure inside the vehicle. We can find that out by plugging in a diagnostic tool.

Safety:

Make sure you are wearing gloves and goggles.

Step 1:

By removing the cover, we can see the common rail system. We're going to start by removing the injector pipe, When you are doing the pipes make sure that any exposed parts are capped because of the risk of contamination. Next, remove the back linkage, on this particular application you're going to have to remove the globe connector using a pair of pliers. Next, remove the electrical connection. This now leaves the retaining clamp holding the injector. Finally, withdraw the injector from the seat.

Step 2:

Fit a repaired injector from the Delphi repair network. Make sure that the injector is the correct part number, all Delphi injectors are vacuum sealed to ensure cleanliness. Prior to fitting the injector, you need to note down the correction code.

Step 3:

To refit the injector you are going to remove the protective cap from the nozzle and slide the injector carefully into its place. Now, refit the retaining clamp. Next, refit the electrical connector, the back leakage, and the glow plug.

Step 4:

Now that we've fitted the injector, we need to refit the high-pressure fuel pipe. Using the correct tooling you’re going to apply the correct torque to the pipe. The physical repair has now been completed.

Step 5:

Enter the code so that the control unit of the vehicle, can tally up with the injector we've just fitted

Step 6:

Lastly, confirm your repair by starting the vehicle up. Now that we've entered the code the control unit and the injector should be tied up.

That's how to replace a Delphi common rail fuel injector. Three key points are safety, cleanliness, and genuine parts.

The specified form no longer exists or is currently unpublished.
serv-wb-banner-large

Contact Us

Visit our Contact hub to find a range of enquiry types suited to help you find the exact support you are looking for.

serv-wr-banner-large

Find your nearest Service & Diesel Centres

Select your Region