Fuel Rail and Injectors Cleaning and Inspection (LCS)

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 CORP.
1. Remove the injectors from the fuel rail.
Fig 2: View of Wiring Harnesses and Injectors
Courtesy of GENERAL MOTORS CORP.
2. Remove the wiring harness from the fuel injectors.
Fig 3: View of Fuel Injector Clamp
Courtesy of GENERAL MOTORS CORP.
3. Remove and discard the fuel injector hold-down clamp.
Fig 4: View of Injector Assembly
Courtesy of GENERAL MOTORS CORP.
4. Remove and discard the fuel injector O-ring and plastic spacer.
Fig 5: View of Injector Assembly
Courtesy of GENERAL MOTORS CORP.
5. Remove and discard the isolator cup and retainer.
Fig 6: View of Injector Seal and Assembly
Courtesy of GENERAL MOTORS CORP.
6. Remove and discard the fuel injector seal.
Fig 7: View of Plastic Housing and Sensor
Courtesy of GENERAL MOTORS CORP.
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 Rail Structure
Courtesy of GENERAL MOTORS CORP.
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 GM P/N 12345610 (Canadian P/N 993193) or equivalent.
    • Lubricate the threads and the sealing cone on the NEW fuel injection fuel rail fuel pressure sensor with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
    • 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: View of Injector Inspector Points
Courtesy of GENERAL MOTORS CORP.
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 Injector O-Ring Assembly
Courtesy of GENERAL MOTORS CORP.
13. Lubricate the NEW O-ring with 5W30 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 CORP.
15. Install the isolator cup and retainer.
Fig 12: View of Seal and Injector
Courtesy of GENERAL MOTORS CORP.
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 Tool EN-4866-2 and Injector
Courtesy of GENERAL MOTORS CORP.
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 CORP.
18. Install a NEW fuel injector hold-down clamp.