Fuel Injector Replacement (Left)

FUEL INJECTOR REPLACEMENT (LEFT)

TOOLS REQUIRED
J-46594 Fuel Injector Remover

REMOVAL PROCEDURE




1. Remove the intake manifold cover.
2. Drain the cooling system. Refer to Draining and Filling Cooling System.
3. Disconnect the negative battery cable.
4. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).

IMPORTANT:
- After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.
- Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

5. Remove the charged air cooler inlet duct connector (4) from the turbocharger.




6. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
7. Open the harness clip (2).
8. Remove the main engine electrical harness connectors.




9. Remove the engine harness main electrical connectors bolts.
10. Remove the main electrical connectors from the bracket.




11. Disconnect the barometric sensor electrical connector.
12. Remove the engine wire harness from the clip.
13. Remove the main electrical harness bracket bolts.
14. Remove the main electrical harness bracket.




15. Disconnect the glow plug control module electrical connectors (1, 2).
16. Remove the positive crankcase ventilation (PCV) hose/pipe.




17. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
18. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
19. Remove the left fuel injector pipes.

NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector.




20. Remove the fuel return hose clips.
21. Remove the fuel return hose from the injectors.




22. Disconnect the fuel injector electrical connectors.

NOTE: Label all the injector electrical connectors before the connectors are removed in order to prevent reconnecting to the wrong injector. Failure to properly connect the injectors in the correct sequence will cause severe engine damage.




23. Remove the fuel injector bracket bolts.




24. Install J-46594 into the bolt hole in the fuel injector bracket.
25. Install a flare nut wrench onto J-46594 and pull back away from the fuel injector, until the injector releases from its seat.
26. Remove J-46594.
27. Remove the fuel injectors with brackets.




28. If necessary, remove the fuel injector bracket pins.
29. If necessary, remove and discard the copper washer from the fuel injector bore.
30. If necessary, remove and discard the O-ring from the fuel injector.

FUEL INJECTOR CLEANING AND INSPECTION

IMPORTANT: If reusing the old injectors perform the following:




1. Use a soft bristle non-metallic brush and top engine cleaner, GM P/N 1052626 or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before re-installation.
2. Inspect the fuel injector nozzle tip (1) for any signs of discoloration (dark yellow, tan or blue) due to excessive heat.
3. Replace the injector if any damage is found.




4. Clean the fuel injector high pressure line.
5. Inspect the fuel injector line for excessive corrosion or damage to the sealing surfaces (1, 2). Replace the line if any damage is found.

INSTALLATION PROCEDURE




1. If necessary, install a NEW O-ring onto the fuel injector.
2. If necessary, install a NEW copper washer to the fuel injector bore.
3. If necessary, install the fuel injector bracket pins.




4. Install the fuel injectors with brackets.




5. Install the fuel injector bracket bolts.

NOTE: Refer to Fastener Notice.

Tighten the bolts to 30 N.m (22 lb ft).




6. Connect the fuel injector electrical connectors.




7. Install the fuel return hose to the injectors.
8. Install the fuel return hose clips.




9. Install the fuel injector pipes.

NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.

Tighten the fittings to 41 N.m (30 lb ft).

10. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
11. Install the PCV hose/pipe.




12. Connect the glow plug control module electrical connector (1,2).




13. Install the main electrical harness bracket.
14. Install the main electrical harness bracket bolts.

Tighten the bolts to 21 N.m (15 lb ft).

15. Connect the barometric sensor electrical connector.
16. Install the engine wire harness to the clip.




17. Install the main electrical connectors to the bracket.
18. Install the engine harness main electrical connectors bolts.

Tighten the bolts to 21 N.m (15 lb ft).




19. Connect the main engine electrical harness connectors.
20. Push down on the latches (1) in order to connect the connectors.
21. Close the harness clip (2).




22. Remove the tape from the turbocharger openings.
23. Install the charged air cooler inlet duct connector (4) to the turbocharger.
24. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).

Tighten the clamp to 6 N.m (53 lb in).

25. Fill the cooling system. Refer to Draining and Filling Cooling System.
26. Connect the negative battery cable.
27. Install the intake manifold cover.
28. If the fuel injectors were replaced, refer to Fuel Injector Flow Rate Programming.
29. Prime the fuel system. Refer to Fuel System Priming.
30. Start the engine. If the engine stalls, repeat the above step.
31. Once the engine starts, inspect for fuel leaks.