Fuel Rail And Injectors Removal

Special Tools

• EN-51146  Fuel Injector Removal/Installation Kit
• EN-51146-100  Fuel Injector Removal Plate

For equivalent regional tools, refer to Special Tools .

WARNING:

Refer to Diesel/Gasoline Vapors Warning .

WARNING:

Refer to Safety Goggles and Fuel Warning .

NOTE:

Maintain a clean work surface when working with fuel rail and fuel injectors. Use care to avoid contaminants on the injector seals.

Fig 1: Fuel Injector Screw
Courtesy of GENERAL MOTORS COMPANY
NOTE:

Remove only one fuel injector screw (2) to perform the length check.

1. Ensure the EN-51146-1-6  demounting screws (1) are used with turbocharger equipped applications. Match the length (a) of the EN-51146-1-6  demounting screws (1) to the length of the fuel injector screw (2). If the length does not match, refer to the Non-Turbocharger procedure.
Fig 2: Continental MGE Demounting Screw
Courtesy of GENERAL MOTORS COMPANY
2. Install the EN-51146-1-6  demounting screws (2) to the EN-51146-1-1  supports (1) and tighten to 7 N.m (62 lb in).
Fig 3: Inner Fuel Injector Screw
Courtesy of GENERAL MOTORS COMPANY
NOTE:

Do not loosen or remove both fuel injector screws for an individual fuel injector at the same time. Ensure the EN-51146-1-6  demounting screw and EN-51146-1-1  support is properly installed on the inner fuel injector screw location before removing the remaining outer fuel injector screw. Ensure the screws do not fall into the cylinder head slot.

3. Remove the inner fuel injector screw (1).
4. Install one EN-51146-1-6  demounting screws and EN-51146-1-1  support (2) and tighten to 5 N.m (44 lb in).
Fig 4: Outer Fuel Injector Screw
Courtesy of GENERAL MOTORS COMPANY
5. Remove the outer fuel injector screw (1).
6. Install a second EN-51146-1-6  demounting screws and EN-51146-1-1  support (2) and tighten to 5 N.m (44 lb in).
Fig 5: Supports
Courtesy of GENERAL MOTORS COMPANY
7. Using the same procedure, install the remaining EN-51146-1-6  demounting screws and EN-51146-1-1  supports (1) for each fuel injector and tighten to 5 N.m (44 lb in).
Fig 6: Upper And Lower Fuel Rail Assembly Bolts
Courtesy of GENERAL MOTORS COMPANY
NOTE:

The fuel rail bolts may remain with the decoupling elements and retainer at the fuel rail assembly.

8. Loosen the 4 upper fuel rail assembly bolts (1) completely from the cylinder head, but do not remove the bolts.
9. Loosen the 4 lower fuel rail assembly bolts (2) completely from the cylinder head, but do not remove the bolts.
Fig 7: Plate, Supports, Bolts And Slide Hammers
Courtesy of GENERAL MOTORS COMPANY
10. Install EN-51146-100  plate (2) to the EN-51146-1-1  supports (1) using the eight plate bolts (3). Counterhold each support with a wrench while tightening the bolt.
11. Install the EN-51146-1-3  slide hammers (4) onto the EN-51146-100  plate (2) using the outer holes.
Fig 8: Removing Fuel 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.

12. Using the EN-51146-1-3  slide hammers (1, 2), begin to remove the fuel injectors by applying slight force equally on both hammers. Observe the alignment of the fuel injectors, and allocate force on the hammers as necessary.
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.

13. Complete the removal of the fuel rail and injector assembly with the EN-51146  remover. The slide hammers may then be removed from the plate.
14. Install the EN-51146-2-5  calibration tools onto the fuel injector tips to protect the injectors.
15. Cover the fuel injector bores at the cylinder head to prevent contamination.