Fuel Injector Replacement Without CTF

1. Tilt the cab. Refer to Cab Tilting in General Information.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical - 7.8L.



4. Disconnect the two-way valve (TWV) harness connectors at the outside of the lower case, under the valve rocker arm cover.
5. Remove the injection pipes between the injector (4) and the supply pump.
6. Disconnect TWV harness connector from inside of the lower case joint connector.
7. Loosen the terminal nuts for TWV harness on the top of the injector and remove the TWV harness.
8. Remove the TWV harness assembly from the top of the rocker arm assembly.
9. Remove the return pipe bolt (2) and the return pipe (3) between the injector and injection.

Caution: Do not forcefully pull the injector pipe free. Doing so will loosen the nozzle sleeve and water leakage may result in damage to the engine.

10. Loosen the injector clamp bolt (1) then remove the injector assembly (4) and clamp (8).

1. Install the injector clamp on the valve spring seat.



2. Assemble the fuel injector (4) and injector clamp (8) as a complete assembly first, then temporarily install the injector assembly together with the clamp (8) into the injector sleeve hole.
3. Temporarily tighten the injection pipe bolt (2) to the injector.

Notice: Refer to Fastener Notice in the Preface section.

4. Apply molybdenum disulfide grease to the clamp bolt (1).

Tighten
Tighten the injector clamp bolt to 31 N·m (22 lb ft).

5. Tighten the injection pipe bolt (2).

Tighten
Tighten the injection pipe to 44 N·m (33 lb ft).

Important: Ensure that the injection pipe and return pipe eye bolt are tightened. This will prevent the dilution of the engine oil. Ensure that the gasket for the return pipe does not ride on the injector body when tightening the eye bolt.

6. Install the fuel return pipe on the injector (1).

Tighten
Tighten the fuel return pipe eye bolt to 14 N·m (124 lb in).




7. Install the TWV harness assembly.

Tighten
Tighten the fixing bolts to 22 N·m (16 lb ft).

8. Install the TWV harness to TWV terminals (1). Tighten the fixing nut by hand until the nut reaches the harness terminals.

Tighten
Tighten the fixing nut to 2 N·m (18 lb in).

9. Reconnect the TWV harness to lower case joint connector.
10. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical - 7.8L.
11. Reconnect the two TWV harness connectors at the outside of the lower case.
12. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
13. Lower the cab.

Fuel Injector Replacement With CTF

1. Tilt the cab. Refer to Cab Tilting in General Information.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Disconnect the 2-way valve (TWV) harness connectors at the outside of the lower case, under the valve rocker arm cover.
4. Remove the injection pipes between the injector and the supply pump.
5. If required, remove the exhaust gas recirculation (EGR) cooler pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls - 7.8L.
6. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical - 7.8L.
7. Disconnect the TWV harness connector from inside the lower case joint connector.



8. Loosen the terminal nuts (1) for the TWV harness on the top of the injector and remove the TWV harness.
9. Remove the TWV harness assembly bracket from the top of the rocker arm assembly.



10. Remove the return pipe eye bolt (2) and the return pipe (3) from the injector (4).

Notice: Do not forcefully pull the injector pipe free. Doing so will loosen the nozzle sleeve and water leakage may result in damage to the engine.

11. Remove the injector clamp bolt (1) and clamp (8) from the cylinder head.
12. Remove the injector assembly (4).

1. Install the injector clamp (8) on the valve spring seat.
2. Assemble the fuel injector (4) and injector clamp (8) as a complete assembly.
3. Temporarily install the injector assembly (4) together with the clamp (8) into the injector sleeve hole (6).
4. Temporarily tighten the injection pipe (5) to the injector (4).

Notice: Refer to Fastener Notice in the Preface section.

5. Apply molybdenum disulfide grease to the clamp bolt (1).

Tighten
Tighten the injector clamp bolt (1) to 31 N·m (22 lb ft).

6. Tighten the injection pipe (5).

Tighten
Tighten the injector pipe bolt to 44 N·m (33 lb ft).

Important: 

•	Ensure the injection pipe and return pipe eye bolts are tightened. This will prevent the dilution of the engine oil.

•	Ensure the gasket for the return pipe does not ride on the injector body when tightening the eye bolt.

7. Install the fuel return pipe (3) on the injector (4) with the return pipe eye bolt (2).

Tighten
Tighten the fuel return pipe eye bolt (2) to 14 N·m (10 lb ft).

8. Install the TWV harness assembly bracket.

Tighten
Tighten the TWV harness bracket bolts to 22 N·m (17 lb ft).




9. Install the TWV harness to the TWV terminals (1). Tighten the nut by hand until the nut reaches the harness terminals.

Tighten
Tighten the TWV terminal nut to 2 N·m (18 lb in).

10. Reconnect the TWV harness to the lower case joint connector.



11. Inspect and record the ID code from the injector.
12. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement in Engine Mechanical - 7.8L.
13. Reconnect the 2 TWV harness connectors at the outside of the lower case.
14. If required, install the EGR cooler pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls - 7.8L.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
16. Lower the cab.
17. Program the ID code.