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PRE-RELEASE

Fuel Injector Replacement

Fuel Injector Replacement



Special Tools

• EN-47909 Injector Bore and Sleeve Cleaning Kit

• EN-48266 Injector Seal Installer and Sizer

• GE-6125-1B Slide Hammer

• EN 3721-A Injector Remover

• EN 39313 Spark Plug Port Adapter


For equivalent regional tools, refer to Special Tools

Removal Procedure


1. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief .

2.
Note

The fuel injectors have an alignment feature. Note the position of the injectors for reinstallation.


Remove the fuel injection fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LF1, LFW) or Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LF1, LFW) .

3. Remove and discard the three fuel injector retaining rings (1).


4. Remove the direct fuel injectors and harness (1) as an assembly, and disconnect the electrical connector (2). If necessary, use the GE-6125-1B slide hammer with the EN 3721-A injector remover in order to remove the direct fuel injectors evenly.


5. Remove and discard the following components from the fuel injectors (4).


• Upper O-ring Seal (1)

• Plastic Spacer (2)

• Retaining Ring (3)

• Isolator Cup (5)

• Teflon Seal (6)

6. Inspect the fuel rail injector bores and clean with the EN 39313 adapter, and EN-47909 cleaning kit, if required.


Installation Procedure


1.
Note

Lubricate a NEW O-ring seal (1) with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .


Install the following NEW components to the fuel injectors. Use steps 2 through 8 to install these components.


• Upper O-ring Seal (1)

• Plastic Spacer (2)

• Retaining Ring (3)

• Isolator Cup (5)

• Teflon Seal (6)

2. From the EN-48266 installer, position the EN 48266-1 to the injector tip.


3.
Note

DO NOT lubricate the NEW teflon seal.


Install a NEW teflon seal onto the EN 48266-1.


4. Pull the NEW teflon seal by hand over the EN 48266-1 and into the groove in the injector.


5. Remove the EN 48266-1 from the injector tip.

6. From the EN-48266 installer, install the EN 48266-2 to the injector tip.


7. Using EN 48266-2, resize the teflon seal. Install the EN 48266-2, until it bottoms out against the injector body, and rotate the EN 48266-2 while applying only moderate force 180 degrees in one direction and then 180 degrees back in the other direction.


8. Remove the EN 48266-2.

9. Install the direct fuel injectors and harness (1) as an assembly and connect the electrical connector (2).


10.
Note

The fuel injectors have an alignment feature and must be reinstalled as noted during removal.


Install the fuel injection fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LF1, LFW) or Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LF1, LFW) .


PRE-RELEASE