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How to remove and replace a diesel common rail injector

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Fuel Systems How to Technicians 1 min read

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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.


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.

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