Fuel Rail and Injectors Cleaning and Inspection

Special Tools

• EN 49245  Injector Seal Installer Kit
• EN 49247  Injector Retaining Clip Installer

For equivalent regional tools, refer to Special Tools .

Fig 1: View Of Fuel Rail Wiring Harness
Courtesy of GENERAL MOTORS COMPANY
1. Disconnect and remove the fuel rail wiring harness (1).
Fig 2: View Of Fuel Injector & Retainer
Courtesy of GENERAL MOTORS COMPANY
2. Taking care not to touch or apply force to the injector tip or electrical connector, remove the fuel injector retainer (1) by spreading both sides at the same time. A large, sturdy snap ring plier can help with this. Discard the retainer.
3. Holding the largest diameter/body of the injector only, indicated by arrow in graphic, and using a slight twisting motion, remove the fuel injector (2) from the fuel rail.
Fig 3: View Of Fuel Injector Components
Courtesy of GENERAL MOTORS COMPANY
4. Using pliers, remove the fuel injector bushing (3) straight out from injector body. Discard bushing (3). Remove and discard the fuel injector O-ring (1) and plastic spacers (2).
5. Remove and discard the fuel injector seals (4).
Fig 4: Identifying Fuel Pressure 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.

6. Remove the fuel pressure sensor (1).
NOTE:

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

7. Clean the exterior of the fuel rail and injectors with solvent.
Fig 5: Identifying Fuel Rail Inspection Areas
Courtesy of GENERAL MOTORS COMPANY
8. Inspect the fuel rail (1) 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 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
Fig 6: Identifying Fuel Pressure 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.

9. Install the fuel pressure sensor (1).
   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. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended lubricant.
   2. Lubricate the threads and the sealing area on the fuel pressure sensor with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended lubricant.
   3. Install the fuel pressure sensor hand tight.
   4. Remove the fuel pressure sensor and re-lubricate.
   CAUTION:

   Refer to Fastener Caution .

   5. Install the fuel pressure sensor and tighten to 33 N.m (25 lb ft).
Fig 7: Identifying Fuel Injector Components
Courtesy of GENERAL MOTORS COMPANY
10. Inspect the fuel injectors for the following conditions:
    • 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)
11. Replace the fuel rail or injector if any damage is found. Do not attempt to repair a fuel rail or injector.
Fig 8: Identifying Fuel Injector Bushing
Courtesy of GENERAL MOTORS COMPANY
NOTE:

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

12. Install NEW fuel injector bushing (1) onto injector body. Bushing should seat with a distinct "snap" sound and feel. Ensure bushing is fully seated.
Fig 9: View Of Injector O-Ring & Spacers
Courtesy of GENERAL MOTORS COMPANY
13. Install the NEW white plastic spacer (3) on the fuel injector first.
14. Install the brown plastic spacer (2) second.
15. Lubricate the NEW O-ring (1) with 5W30 engine oil.
Fig 10: View Of Injector Assembly
Courtesy of GENERAL MOTORS COMPANY
NOTE:

Do NOT install the Teflon injector tip/bore seals until AFTER the injectors are installed on the fuel rail.

16. 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).
17. Clamp the fuel rail in a bench vise USING SOFT JAWS to aid in holding the rail during the installation of the retainer.
Fig 11: Retainer Installer
Courtesy of GENERAL MOTORS COMPANY
NOTE:
Ensure the retainer is set properly into EN 49247  installer.
• The notch should always face forward (1)
• The retainer should be behind the plate (2)
• The tool windows allow for visual alignment (3)
18. Install the fuel injector retainer onto the EN 49247  installer.
Fig 12: Installing The Retainer Properly
Courtesy of GENERAL MOTORS COMPANY
19. Note the following points when preparing to use the EN 49247  installer.

    There is a 15-degree angle of rotation (1) with the fuel rail flanges relative to the fuel rail. You must hold the EN 49247  installer at a similar angle to ensure installing the retainer properly.

Fig 13: Positioning Retainer Installer
Courtesy of GENERAL MOTORS COMPANY
20. The retainer (1) should almost touch the electrical connector (2), and the base of the EN 49247  installer should be positioned as shown before you begin to squeeze the tool to complete the installation. This will help ensure the retainer is properly located relative to the injector and fuel rail flanges.
Fig 14: Installing Fuel Injector Retainer
Courtesy of GENERAL MOTORS COMPANY
21. Holding the injector bushing (2) and fuel rail flanges (1) in alignment, and holding the injector assembly firmly against the fuel rail so there is no gap between (1) and (2), install the fuel injector retainer (3).
Fig 15: Identifying Fuel Rail Flanges
Courtesy of GENERAL MOTORS COMPANY
CAUTION:

Ensure the fuel injector retainer is properly installed. Failure to completely install the retainers may degrade fuel injection system performance or cause system malfunction.

22. Ensure all 3 fuel injector bushing tabs and fuel rail flanges (1) are properly and completely captured by the fuel injector retainer.
23. Repeat for remaining injectors until all are installed and retained in fuel rail.
Fig 16: View Of Fuel Rail Wiring Harness
Courtesy of GENERAL MOTORS COMPANY
24. Install the fuel rail wiring harness (1).
Fig 17: Installing Seals With Long Protector
Courtesy of GENERAL MOTORS COMPANY
NOTE:

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

25. 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.
26. 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.

27. Compress the seal with your fingers, then resize the seal using the EN-49245-4  sizer (5).
Fig 18: Installing Seals With Short Protector
Courtesy of GENERAL MOTORS COMPANY
NOTE:

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

28. Install EN-49245-2  short protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN-49245-2  short protector.
29. 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.

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