Fuel Rail and Injectors Cleaning and Inspection

Special Tools 

EN-49245  Injector Seal Installer Kit

Equivalent regional tools:Special Tools (LF3) , or Special Tools (LGX)

1. Fuel Injector Wiring Harness(1) - Disconnect

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2. Taking care not to touch or apply force to the injector tip or electrical connector, remove the fuel injector (1) by pressing down on the retainer lever to release the tab (2) and simultaneously rotating the injector 45 degrees and pulling straight out from the fuel rail.

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3. Remove and DISCARD the fuel injector retainer (3) from the fuel injector.
4. Using pliers, remove and DISCARD the fuel injector bushing (3) straight out from injector body.

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5. Remove and DISCARD the fuel injector O-ring (1) and plastic spacers (2).
6. Fuel Injector Seal(4) - Remove and DISCARD(x2).
7. Fuel Pressure Sensor(1) - Remove

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   NOTE:

   Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.

NOTE:

Do not soak or submerge the fuel rail or injectors in solvent.

8. Clean the exterior of the fuel rail and injectors with solvent.
9. Inspect the fuel rail (1) and components for the following conditions:

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   • Damage, debris or restrictions to the fuel rail
   • Damage, debris or restrictions to the fuel ports in the fuel rail
   • Damage to the mounting area for the fuel rail
   • Damage to the fuel rail mounting bolts or mounting bolt grommets/isolators
   • Damage to the threads on the fuel rail feed fitting
   • Damage to the threads in the fuel pressure sensor bore
   • Damage to the fuel pressure sensor connector, threads, or sealing face
10. Install the fuel pressure sensor (1).

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    NOTE:

    Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.

    NOTE:

    Ensure that the fuel rail threads have been cleaned of any excess fuel or the fuel pressure sensor will NOT seal properly.

    1. Lubricate the threads and the sealing area in the fuel rail with silicon free engine oil. Adhesives, Fluids, Lubricants, and Sealers (LF3) , or Adhesives, Fluids, Lubricants, and Sealers (LGX)
    2. Lubricate the threads and the sealing area on the fuel pressure sensor with silicon free engine oil. Adhesives, Fluids, Lubricants, and Sealers (LF3) , or Adhesives, Fluids, Lubricants, and Sealers (LGX)
    3. Fuel Pressure Sensor(1) - Install and hand tighten
    4. Fuel Pressure Sensor(1) - remove and re-lubricate.
    CAUTION:

    Refer to Fastener Caution .

    5. Fuel Pressure Sensor(1) - Install and tighten 33 N.m (25 lb ft).
11. Inspect the fuel injectors for the following conditions:

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    • Damage to the fuel injector connector (1)
    • Damage to the fuel inlet cone (2)
    • Damage to the fuel injector body (3)
    • Damage to the fuel injector tip (4)
12. Replace the fuel rail or injector if any damage is found. Do not attempt to repair a fuel rail or injector.
13. Install NEW fuel injector bushing (1) onto injector body. Bushing should seat with a distinct "snap" sound and feel. Ensure bushing is fully seated.

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    NOTE:

    The fuel injector bushing (1) is to be installed BEFORE O-ring or backup rings are installed.

14. Install a NEW white plastic spacer (3) on the fuel injector first.

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15. Install a NEW brown plastic spacer (2) second.
16. Lubricate the NEW O-ring (1) with one drop of clean engine oil.
17. The right side (bank 1) fuel injector wiring harness connectors (1) should point to the rear of the engine. The left side (bank 2) fuel injector wiring harness connectors (2) should point to the front of the engine.

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    CAUTION:

    Ensure the fuel injectors are installed in the correct orientation. Improper orientation of the fuel injectors may result in engine misfire and possible engine damage.

18. Install NEW fuel injector retainer (3) onto the fuel injector.

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19. Holding the largest diameter/body of the injector only, indicated by arrow in graphic, insert the injector assembly (1) into the fuel rail. Ensure correct orientation of the electrical connector (2).
20. Rotate the fuel injector approximately 45 degrees until the tab on the retainer (4) locks into the notch on the fuel rail.
21. Repeat for remaining injectors until all are installed and retained in fuel rail.
22. Fuel Injector Wiring Harness(1) - Install

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23. Install EN 49245-1  long protector (3) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a NEW seal (2) on EN-49245-1  long protector.

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    NOTE:

    Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector tip.

24. Using EN-49245-3  pusher (1), install the seal into the second recessed area (4) of the fuel injector.
NOTE:

The EN-49245-4  sizer is two sided, and either direction will size the seal correctly.

25. Compress the seal with your fingers, then resize the seal using the EN-49245-4  sizer (5).
26. Install EN-49245-2  short protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN-49245-2  short protector.

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    NOTE:

    Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector tip.

27. Using EN-49245-3  pusher (1), install the seal into the first recessed area (4) of the fuel injector.
NOTE:

The EN-49245-4  sizer is two sided, and either direction will size the seal correctly.

28. Compress the seal with your fingers, then resize the seal using the EN-49245-4  sizer (5).