Cleaning Fuel Injectors Removal - Dodge Sprinter 2006 Manual

14 - 38 FUEL INJECTION
INJECTOR CLASSIFICA TION PROCEDURE
(1) Tu r n ign it ion swit ch "ON".
(2) Usin g a DRB III
MISCE LLANE OUS.
(3) Select LE ARN INJ E CTORS.
(4) Usin g t h e u p a n d down a r r ows, scr oll t o t h e
a ppr opr ia t e in ject or.
(5) Usin g t h e r igh t a n d left a r r ows, set in ject or t o
pr oper cla ssifica t ion .
(6) On ce in ject or s a r e cla ssified, cycle ign it ion t o
com plet 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) Sea l t h e in ject or h oles in side t h e cylin der h ea d
r ecesses.
(2) Wipe ou t in ject or r ecesses wit h a n on -woven
clot h , t h en clea n wit h a cylin der br u sh .
(3) Clea n t h e bot t om of t h e cylin der r ecess wit h a
r ou n d br u sh .
(4) Blow ou t t h e r ecess a n d clea n a ga in wit h a
n on -woven clot h a n d cover over.
(5) P er for m t h ese st eps for ea ch in ject or r ecess.
NOTE: DO NOT clean the tip of the injector with a
wire brush. Use a non - woven cloth.
(6) Clea n in ject or body wit h a wir e br u sh .
(7) Clea n in ject or t ips wit h a n on -woven clot h .
NOTE: Do Not apply antiseize lubricant to the injec-
tor nozzle area.
(8) Gr ea se in ject or body wit h a n t i seize lu br ica n t .
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-
a n d select E NGINE t h en
pound before installing. Keep lubricant away from
the injector nozzle.
(1) Discon n ect n ega t ive ba t t er y ca ble.
(2) Rem ove en gin e cover (Refer t o 9 - E NGINE -
RE MOVAL).
(3) Rem ove t h e fu el r et u r n h ose lockin g cla m ps a t
t h e in ject or a n d r em ove r et u r n h ose.
(4) Discon n ect t h e in ject or elect r ica l con n ect or
(F ig. 13).
NOTE: Counterhold injection lines with wrench
socket at threaded connections of injectors.
(5) Discon n ect fu el in ject or h igh pr essu r e lin e (F ig.
13).
(6) Rem ove fu el in ject or r et a in in g bolt a n d t en sion
cla w, t h en r em ove t h e in ject or a n d sea l (F ig. 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) Rem ove in ject or s (F ig. 13).
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
(8) Clea n in ject or s a n d r ecesses (Refer t o 14 -
F UE L SYSTE M/F UE L INJ E CTION/F UE L INJ E C-
TOR - STANDARD P ROCE DURE ).
VA