Fuel Rail and Injectors Cleaning and Inspection

Special Tools

• EN-47909  Injector Bore and Sleeve Cleaning Kit
• EN-48266  Injector Seal Installer and Sizer

For equivalent regional tools, refer to Special Tools .

Fig 1: View of Injector Assembly
Courtesy of GENERAL MOTORS COMPANY
1. Remove the injectors from the fuel rail.
Fig 2: View Of Wiring Harness & Injectors
Courtesy of GENERAL MOTORS COMPANY
2. Remove the wiring harness from the fuel injectors.
Fig 3: View of Fuel Injector Clamp
Courtesy of GENERAL MOTORS COMPANY
3. Remove and discard the fuel injector hold-down clamp.
Fig 4: View Of Fuel Injector O-ring & Plastic Spacer
Courtesy of GENERAL MOTORS COMPANY
4. Remove and discard the fuel injector O-ring and plastic spacer.
Fig 5: View Of Isolator Cup & Retainer
Courtesy of GENERAL MOTORS COMPANY
5. Remove and discard the isolator cup and retainer.
Fig 6: View of Injector Seal and Assembly
Courtesy of GENERAL MOTORS COMPANY
6. Remove and discard the fuel injector seal.
Fig 7: View of Plastic Housing & Sensor
Courtesy of GENERAL MOTORS COMPANY
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.

7. Remove and discard the fuel pressure sensor.
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.
Fig 8: View Of Fuel Rail & Components
Courtesy of GENERAL MOTORS COMPANY
9. Inspect the fuel rail and components for the following conditions:
   • 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
   • Damage to the threads on the fuel rail feed fitting
   • Damage to the threads in the fuel pressure sensor bore
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.

10. Install the fuel pressure sensor.
    NOTE:

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

    • Lubricate the threads and the sealing cone in the fuel rail with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended lubricant.
    • Lubricate the threads and the sealing cone on the NEW fuel injection fuel rail fuel pressure sensor with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended lubricant.
    • Install the NEW fuel injection fuel rail fuel pressure sensor hand tight.
    • Remove the NEW fuel injection fuel rail fuel pressure sensor, re-lubricate following steps 1 and 2 above.
    CAUTION:

    Refer to Fastener Caution .

    • Install the NEW fuel injection fuel rail fuel pressure sensor and tighten to 33 N.m (25 lb ft).
Fig 9: Identifying Fuel Injector Inspection Areas
Courtesy of GENERAL MOTORS COMPANY
11. Inspect the fuel injectors for the following conditions:
    • Damage to the fuel injector connector (1)
    • Damage to the injector locator tab (2)
    • Damage to the fuel inlet cone (3)
    • Damage the plastic fuel injector body (4)
    • Damage to the isolator cup retainer groove (5)
    • Damage to the teflon seal (6)
    • Damage to the fuel injector tip (7)
12. Replace the fuel rail or injector if any damage is found. Do not attempt to repair a fuel rail or injector.
Fig 10: View Of Fuel Injector Plastic Spacer & O-Ring
Courtesy of GENERAL MOTORS COMPANY
13. Lubricate the NEW O-ring with one drop of clean engine oil.
NOTE:

The plastic spacer has a top and a bottom. The top, O-ring sealing area, is wider.

14. Install the NEW plastic spacer and O-ring on the injector.
Fig 11: View of Isolator Cup, Retainer and Injector
Courtesy of GENERAL MOTORS COMPANY
15. Install the isolator cup and retainer.
Fig 12: View of Seal & Injector
Courtesy of GENERAL MOTORS COMPANY
NOTE:

Do not use any type of lubricant when installing the NEW seal.

16. Install a NEW seal on the injector using the EN-48266-1  . The seal must be installed/slid into the recessed area of the fuel injector.
Fig 13: View of special Tool EN-4866-2 & Injector
Courtesy of GENERAL MOTORS COMPANY
17. Compress the seal with your fingers before resizing the seal using the EN-48266-2  .
Fig 14: View of Injector Assembly
Courtesy of GENERAL MOTORS COMPANY
18. Install a NEW fuel injector hold-down clamp.
Fig 15: Injector Banks
Courtesy of GENERAL MOTORS COMPANY
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.

19. 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.