Direct Fuel Injection Fuel Rail Installation

Special Tools 

EN-51955  Fuel Injector Seal Install/Sizer

Equivalent regional tools: Special Tools 

1. Clean the fuel injector bores and clean the fuel injectors, if the fuel injectors will be re-installed. Direct Fuel Injection Fuel Rail Cleaning and Inspection 

2. Courtesy of GENERAL MOTORS COMPANY

   NOTE:

   • DO NOT use any type of lubricant when installing the NEW combustion fuel injector seal on the fuel injector tip.
   • Only one combustion fuel injector seal is used on each direct fuel injector, located on the recessed area of the fuel injector tip closest to the end.

   Install the EN-51955-2  short protector (4) onto the fuel injector tip. Place a NEW combustion fuel injector seal (2) on the EN-51955-2  short protector (4).

3. Using the EN-51955-4  pusher (3), install the combustion fuel injector seal (2) into the recessed area (1) of the fuel injector, then remove the EN-51955-2  short protector.

4. Courtesy of GENERAL MOTORS COMPANY

   Compress the combustion fuel injector seal (1) using the EN-51955-3  pre-sizer (2).

5. Courtesy of GENERAL MOTORS COMPANY

   Using the EN-51955-5  sizer (2), resize the combustion fuel injector seal (1).

6. Install one combustion fuel injector seal on each of the remaining direct fuel injectors using the same procedure.

7. Courtesy of GENERAL MOTORS COMPANY

   NOTE:

   Check that the gaps of the two fuel injector seal retainers are aligned.

   Fuel Injector Seal Retainer - Red (3) - Install NEW [3x]

8. Fuel Injector Seal Retainer - White (2) - Install NEW [3x]
9. Fuel Injector Seal (1) - Install NEW [3x]

10. Courtesy of GENERAL MOTORS COMPANY

    NOTE:

    • Lubricate the fuel injector seal with engine oil.
    • Note the orientation of the fuel injector retainers when installed.

    Direct Fuel Injector (3) @ Direct Fuel Injection Fuel Rail (1) - Install [3x]

11. Connect the electrical connector. (4) [3x]
12. Fuel Injector Retainer (2) - Install NEW [3x]

13. Courtesy of GENERAL MOTORS COMPANY

    Direct Fuel Injection Fuel Rail (2) - Install

14. Fuel Injection Fuel Rail Bolt (1) - Loosely install [4x]

15. Courtesy of GENERAL MOTORS COMPANY

    NOTE:

    Tighten only the 2 fuel injection fuel rail bolts shown until the direct fuel injection fuel rail is seated to the cylinder head.

    Tighten the fuel injection fuel rail bolt (1) by hand 1/2 turn.

16. Tighten the fuel injection fuel rail bolt (2) by hand 1/2 turn.
17. Continue to tighten these two bolts by hand in 1/2 turn increments until the direct fuel injection fuel rail is seated to the cylinder head.
18. Fig 1: Identifying Fuel Injection Fuel Rail Bolts With Tightening Sequence

    Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Fastener Caution

    Fuel Injection Fuel Rail Bolt (1) - Tighten in sequence [4x] 36 N.m (27 lb ft)