Fuel Injector Replacement

Fuel Injector Replacement (LLT)


Tools Required
* EN-47909 Injector Bore and Sleeve Cleaning Kit
* EN-48266 Injector Seal Installer and Sizer
* J 2619-01 Slide Hammer
* J-37281-A Injector Remover



Removal Procedure

1. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027 - LP1, LY7) (Fuel Pressure Relief (With CH 48027) (LY7) VIN 7 W/O Direct Fuel Injection)Fuel Pressure Relief (Without CH 48027 - LP1, LY7) (Fuel Pressure Relief (Without CH 48027) VIN 7 W/O Direct Fuel Injection)Fuel Pressure Relief (With High Pressure Pump - LLT) (Fuel Pressure Relief (With High Pressure Pump (LLT) VIN V W/ Direct Fuel Injection) .

Important: The fuel injectors have an alignment feature, note the position of the injectors alignment for installation.


2. Remove the fuel injection fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LLT) (Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LLT) VIN V W/ Direct Fuel Injection) or Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LLT) (Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LLT) VIN V W/ Direct Fuel Injection) .
3. Remove and discard the fuel injector hold down clamp.
4. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.




5. Remove the direct fuel injectors (1). If necessary, use the J 2619-01 and the J-37281-A in order to remove the direct fuel injector(s).




6. 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)




Installation Procedure






Important: Lubricate a NEW O-ring seal (1) with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.


1. 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 , position the EN 48266-1 to the injector tip.





Important: DO NOT lubricate the NEW seal.


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




4. Pull the NEW 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 , install the EN 48266-2 to the injector tip.




7. Using the EN 48266-2, resize the 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 (1) to the cylinder head.
10. Install the NEW direct fuel injector hold down clamps.
11. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.

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


12. Install the fuel injection fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LLT) (Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LLT) VIN V W/ Direct Fuel Injection) or Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LLT) (Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LLT) VIN V W/ Direct Fuel Injection) .