Fuel Rail Removal

Special Tools 

EN-51146  Fuel Injector Removal/ Installation Kit

Equivalent regional tools: Special Tools 

1. Loosen the 2 fuel rail bolts (3) from the cylinder head and from the camshaft bearing rear cap completely, but do not remove the bolts.
   WARNING: Gasoline/Gasoline Vapors Warning
   WARNING: Safety Goggles and Fuel Warning
   NOTE: When working on the fuel rail and fuel injectors, always maintain a clean work surface. Failure to follow this caution can result in contaminants on the injector seals and cause leaks.
   Fig 1: Fuel Rail Bolts

   Courtesy of GENERAL MOTORS COMPANY
   NOTE: The fuel rail bolts remain with decoupling elements and retainer at the fuel rail assembly.
2. Loosen the 8 fuel rail bolts (1, 2) from the cylinder head completely, but do not remove the bolts.
3. Remove the fuel injector bolt (1) from the fuel injector cylinder 1 (2) at the rail side.
   Fig 2: Fuel Injector Bolt

   Courtesy of GENERAL MOTORS COMPANY
   NOTE: Never loosen both bolts at the same time. Failure to follow this caution could cause leaks or malfunction after installation.
   NOTE: Pay attention, that the bolt does not fall into the cylinder head slot.
4. Install the EN-51146-1-6  demounting screw (2) to the EN-51146-1-1  support (1) and tighten to 7 N.m (62 lb in).
   Fig 3: Demounting Screw

   Courtesy of GENERAL MOTORS COMPANY
   CAUTION: Fastener Caution
5. Install the EN-51146-1-1  support to the fuel injector cylinder 1 (2) and tighten to 5 N.m (44 lb in).
   Fig 4: Support And Cylinder 1 Fuel Injector

   Courtesy of GENERAL MOTORS COMPANY
6. Remove the fuel injector bolt (1) from the fuel injector cylinder 1 (2).
   Fig 5: Fuel Injector Cylinder

   Courtesy of GENERAL MOTORS COMPANY
7. Install the EN-51146-1-6  demounting screw to the EN-51146-1-1  support and tighten to 7 N.m (62 lb in).
8. Install the EN-51146-1-1  support (1) to the fuel injector cylinder 1 (2) and tighten to 5 N.m (44 lb in).
   Fig 6: Support And Cylinder 1 Fuel Injector

   Courtesy of GENERAL MOTORS COMPANY
9. Repeat the steps 3 - 8 for the other 3 injectors.
10. Install the EN-51146-1-2  plate (1) to the 8 EN-51146-1-1  supports (3).
    Fig 7: Plate Bolts

    Courtesy of GENERAL MOTORS COMPANY
    NOTE: Mind the arrow on the EN-51146-1-2  plate. The arrow must show in driving direction.
11. Install the 8 plate bolts (2).
12. Tighten 8 plate bolts (2) and counterhold with a wrench at the EN-51146-1-1  supports (3).
13. Install the 2 EN-51146-1-3  sliding hammers (1) to the EN-51146-1-2  plate (2).
    Fig 8: Sliding Hammers

    Courtesy of GENERAL MOTORS COMPANY
14. Using the 2 EN-51146-1-3  sliding hammers, begin to remove the fuel injectors by applying slight force equally on both hammers. Observe the alignment of the fuel injectors (2) and allocate force on the hammers as necessary.
    Fig 9: Removing Injectors

    Courtesy of GENERAL MOTORS COMPANY
    NOTE: The alignment of the fuel injectors within the cylinder bores is critical for fuel injection system function. Use equal force on each slide hammer to ensure the fuel injectors are removed without tilting in the injector bore.
15. Remove the fuel injector rail assembly and install the EN-51146-1-2  plate with the fuel injector assembly to a bench vise.
    Fig 10: Plate Installed In Vise

    Courtesy of GENERAL MOTORS COMPANY
    CAUTION: After removal of the fuel injection fuel rail assembly, check the completeness of the assembly. Check that no decoupling elements, fuel rail bolts or fuel injector seals remain near the fuel injector bores on the cylinder head. Failure to perform this can result in poor engine performance or engine damage.
    NOTE: After removing the fuel rail and injector assembly, position the assembly on a clean work surface with the fuel injectors on top. Do not allow the weight of the assembly to rest on the fuel injectors.
16. Install the 4 EN-51146-2-5  calibration tools (2) rotary to the fuel injectors (1), as shown in the graphic.
    Fig 11: Calibration Tools And Fuel Injectors

    Courtesy of GENERAL MOTORS COMPANY
    NOTE: The EN-51146-2-5  calibration tools are also used to protect the fuel injectors.
17. Cover the fuel injector bores at the cylinder head, to prevent for dirt.
18. EN-51146-1-3  sliding hammers - Remove [2x].
19. EN-51146-2-5  calibration tools - Remove [4x]
20. Inspect all fuel injectors for damage.
21. Remove the 2 combustion seals (2) at each fuel injector, use EN-51146-2-1  stylus (1).
    Fig 12: Combustion Seals And Stylus

    Courtesy of GENERAL MOTORS COMPANY
    NOTE: Always use the stylus from the EN-51146  fuel injector kit fuel injector kit. Never use a metal tool in place of the stylus. Use of another tool can damage the fuel injector and could cause to leakage.
22. Inspect all fuel injectors for damage again.