Depressurize fuel and disconnect injector electrical connector and any rail lines needed to free the injector top. Remove retaining clip(s).
Select correct FUERD adapter that matches the injector top, flange, or threaded section. For plastic tops use soft or crush-resistant adapters.
Attach adapter and puller ensuring the puller is centered and aligned axially with the injector bore — misalignment increases risk of bore damage.
Apply controlled axial force.
With a slide-hammer: use short, controlled blows rather than long, violent swings.
With hydraulic puller: increase pressure slowly and evenly.
If the injector moves, continue until it is fully extracted. Re-apply penetrating oil if progress stalls.
If the injector does not budge after careful, controlled attempts: stop. Consider heat around the injector head (avoid plastics and sensors) or consult a machine shop. Never use pry grips or chisels that apply uneven force.
Inspect injector and bore — look for carbon build-up, scoring, or corrosion. If there is visible damage or fragments, do not reinstall and consult a machine shop.
Clean the bore with vacuum + compressed air. Do not push debris into cylinders.
Replace O-rings and seals (always new). Lightly lubricate O-rings with clean engine oil for installation.
Reinstall injector straight and to OEM torque (typical injector clamp torque range is 15–25 Nm, but verify with the vehicle manual).
Reconnect lines, re-pressurize fuel system, and check for leaks before starting engine. Clear fault codes if needed. Monitor for idle and leak issues.
Pre-soak overnight for high-mileage or diesel heads with heavy carbon.
Keep soft jaws and non-marring adapters on hand for fragile plastic injector tops.
Photograph connectors/steps during disassembly for faster reassembly.
For fleets: maintain O-ring service kits and adapter sets to reduce downtime.
Injector fractures inside the bore.
After repeated controlled attempts with no movement.
Visible bore scoring or metal fragments. At that point, further in-house attempts risk expensive head damage - call a machine shop or FUERD technical support.
Q: Can I use vise grips?
A: No — they apply uneven force and risk breaking the injector or scoring the bore. Use a dedicated puller.
Q: Will a slide-hammer damage the head?
A: Used correctly and axially, no. Excessive or angled force can cause damage; hydraulic pullers provide gentler, more controlled force.
Q: Should I replace seized injectors?
A: If the injector is functionally compromised (spray pattern, electrical), replace it. If physically intact, replace seals and bench-test.
