Fuel Rail and Injectors Cleaning and Inspection

WARNING: This page is about a different variant/trim than selected.

Special Tools

EN-49245 Injector Seal Installer Kit
EN-51097 Injector Retaining Clip Installer and Sizer
EN-51105 Injector Seal Installer and Sizer

For equivalent regional tools, refer to Special Tools .

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Disconnect and remove the fuel rail wiring harnesses (1).
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Remove and discard the fuel injector retainer clips (1) by installing EN-51097 injector retaining clip installer and spreading both sides of the clip evenly.
Remove the fuel injector collars (2).
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NOTE:
Some vehicles were not originally equipped with fuel injector dust seals. A NEW seal must be installed when the injectors are removed.

Remove and DISCARD the fuel injector dust seal (1).
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CAUTION:
Do not use a metal tool to remove O-rings, spacers or injector seals. Care must be taken not to scratch or damage the tubes of the injector.

Remove and discard the fuel injector O-ring (1) and plastic spacer (2).
Remove and discard the fuel injector seals (3).
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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.

Remove the fuel pressure sensor (1) from the LH fuel rail.

NOTE:

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

Clean the exterior of the fuel rail and injectors with solvent.
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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 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
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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.

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.

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.
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.
Install the fuel pressure sensor hand tight.
Remove the fuel pressure sensor and re-lubricate.

CAUTION:

Refer to Fastener Caution .

Install the fuel pressure sensor and tighten to 33 N.m (24 lb ft)
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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 O-ring (cracking, splitting, tearing) and the O-ring sealing surface (3)
  Damaged O-rings can result in fuel odor, fuel leaks, and other symptoms. Refer to Symptoms - Engine Controls .
- Damage to the fuel injector body (4)
- Damage to the fuel injector tip (5)
Replace the fuel rail or injector if any damage is found. Do not attempt to repair a fuel rail or injector.
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NOTE:
If there was not previously a dust seal installed on the fuel injector, install a new one.

Install a NEW fuel injector dust seal (1).
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Install a NEW spacer (2) on the fuel injector.
Lubricate the NEW O-ring (1) with a drop of clean engine oil and install on injector.
Install injector collar (3) on fuel injector.
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NOTE:
Do NOT install the injector tip/bore seals until AFTER the injectors are installed on the fuel rail.

Lubricate the socket (3) of the fuel rail with clean engine oil. Holding the largest diamenter/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). LH Rail: Electrical connectors face the front of the engine. RH Rail: Electrical connectors face the rear of the engine.
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Install the fuel injector clip onto the EN-51097 injector retaining clip installer.
Using EN-51097 injector retaining clip installer spread the retainer clip (1) and install onto the fuel rail. Inspect the front and side windows of the retainer clip to ensure that the flange on the rail (3) and the tab on the injector collar (2) are completely captured and firmly seated in the retainer clip (1) as shown.
Repeat for remaining injectors until all are installed and retained in fuel rail.
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Install the fuel rail wiring harnesses (1).
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NOTE:
Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector.

Install EN-51105-1 long protector (3) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a new seal (2) on EN-51105-1 long protector.
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.

Compress the seal with your fingers, then resize the seal if using the EN-49245-4 sizer (5).
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NOTE:
Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector.

Install EN-51105-2 short protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN-51105-2 short protector.
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.

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