38. Fuel Rail and Injectors Cleaning and Inspection
Fuel Rail and Injectors Cleaning and Inspection (LAF, LEA, or LUK)
Special Tools
* EN-49245 - Fuel Injector Seal Installer and Sizer
* EN-49247 - Injector Retaining Clip Installer
For equivalent regional tools, refer to Special Tools Special Tools.
1. Disconnect the electrical connections from the fuel injectors (1).
Note:
Support the fuel rail along the bottom, indicated by the arrow. Support the fuel injector at the widest point, indicated by the arrow. DO NOT support or hold the fuel injector by the tip or connector when removing the fuel injector retainer.
2. Remove and discard the fuel injector retainer (2).
Note:
Support the fuel injector at the widest point, indicated by the arrow. Support the fuel rail at the point indicated by the arrow.
* DO NOT support or hold the fuel injector by the tip or connector
* DO NOT tilt or excessively twist the injector during removal
3. Remove the injectors (1) from the fuel rail by pulling straight out along the fuel injector axis. Slight rotation of the fuel injector is acceptable.
Note:
Support the fuel injector at the widest point, and directly behind the bushing location, indicated by the arrows. DO NOT support or hold the fuel injector by the tip or connector when removing the fuel injector bushing.
4. Using a suitable tool, remove the fuel injector bushing (1) by pushing straight off at the bushing tabs, indicated by the arrows. Discard the bushing.
5. Remove and discard the fuel injector O-ring (3) and plastic spacers (2).
6. Remove and discard the fuel injector seals (1).
Note:
Do not soak or submerge the fuel rail or injectors in solvent.
7. Clean the exterior of the fuel rail (1) and injectors in solvent.
8. 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 fuel feed fitting
9. Replace the fuel rail if any damage is found. Do not attempt to repair a fuel rail.
Caution:
Refer to Fastener Caution Fastener Caution.
10. Inspect the fuel pressure sensor (3) for damage.
1. Disconnect the harness connector (2) from the fuel pressure sensor.
2. Remove the fuel pressure sensor. Dry the fuel pressure sensor bore in the fuel rail with a lint free cloth. The bore should be free of fuel, debris, and burrs.
3. Lubricate the fuel rail fuel pressure sensor bore with clean engine oil.
4. Lubricate the threads and sealing area on the fuel pressure sensor with clean engine oil.
5. Install the fuel pressure sensor hand tight.
6. Remove the fuel pressure sensor and re-lubricate the bore, threads, and sealing area.
7. Install the fuel pressure sensor and tighten to 33 Nm (25 lb ft).
8. Connect the harness connector to the fuel pressure sensor.
11. Inspect the fuel injectors for the following conditions:
* Damage to the fuel injector connector (7)
* Damage to the fuel injector harness connector
* Damage to the fuel injector tip (1)
* Damage to the tolerance ring (2)
12. Replace the fuel injector if any damage is found. Do not attempt to repair a fuel injector.
13. Install a new fuel injector bushing (3) onto the fuel injector. The bushing should seat with a distinct "snap" sound and feel.
Note:
DO NOT reverse the order of the plastic spacers. Identify the correct order in which the new plastic spacers are installed by the color of the spacer.
14. Install the new white plastic spacer (4) on the fuel injector first.
15. Install the new brown plastic spacer (5) second.
16. Lubricate the new O-ring (6) with 5W30 engine oil.
17. Install the O-ring on the injector.
Note:
The injector must be fully installed and properly aligned with the fuel rail in order to install the retainer.
18. Install the fuel injectors (1) into the fuel rail.
* Ensure the fuel injector is fully seated in the fuel rail, and no gaps are present (2).
* Ensure the injector and fuel rail flanges are aligned (3)
Note:
Ensure the retainer is set properly into EN-49247 - installer.
* The notch should always face forward (1)
* The retainer should be behind the plate (2)
* The tool windows allow for visual alignment (3)
19. Install the fuel injector retainer onto the EN-49247 - installer.
Note:
Ensure the tool is resting on the flange of the injector bushing (1).
20. Using EN-49247 - installer, install the fuel injector retainer.
Caution:
Ensure the fuel injector retainer is properly installed. Failure to completely install the retainers may degrade fuel injection system performance or cause system malfunction.
21. Inspect each installed fuel injector retainer, and ensure the retainer is fully seated on the fuel rail and fuel injector bushing flanges (1). The flanges on each side and at the top of the fuel injector should seat completely into the window on the retainer.
22. Connect the electrical connection to the fuel rail.
23. Connect the fuel rail harness connectors (1) to the fuel injectors.
Note:
Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector tip.
24. Install EN-49245-1 - long protector (3) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a NEW seal (2) on EN-49245-1 - long protector.
25. 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.
26. Compress the seal with your fingers, then resize the seal using the EN-49245-4 - sizer (5).
Note:
Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector tip.
27. Install EN-49245-2 - short protector (3) onto the fuel injector tip. Place a NEW seal (2) on EN-49245-2 - short protector.
28. 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.
29. Compress the seal with your fingers, then resize the seal using the EN-49245-4 - sizer (5).