Fuel Injector: Service and Repair

Direct Fuel Injector Replacement

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. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector.
2. Remove the intake manifold.




3. Remove the fuel injector insulator.




4. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief (Low Pressure Side with CH 48027-100) Fuel Pressure Relief (Low Pressure Side w/o CH 48027-100) Fuel Pressure Relief (High Pressure Side).
5. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
6. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.




7. Remove the high pressure fuel pump cover bolts.
8. Remove the high pressure fuel pump cover.




9. Remove the high pressure fuel pump insulator.




10. Loosen the high pressure fuel pipe fitting at the fuel pump.
11. Loosen the high pressure fuel pipe fitting at the fuel rail.
12. Remove and discard the high pressure fuel pipe.




13. Disconnect the fuel injector wiring harness electrical connectors (2) from the fuel injectors.
14. Remove the fuel rail bolts (1).


Important: Carefully remove the fuel rail. The fuel injectors may come out of the cylinder head with the fuel rail.

15. Carefully remove the fuel rail (2).




16. Remove and discard the direct fuel injector hold down clamps.




17. Remove the direct fuel injectors.




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




19. Remove and discard the upper O-ring seal (1) and plastic spacer (2) from the injector(s).
20. Carefully remove and discard the lower nylon seal (4) from the injector(s).

Installation Procedure




1. Install a NEW plastic spacer (2) onto the fuel injector(s).
2. Lubricate a NEW O-ring seal (1) with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
3. Install the NEW O-ring seal (1) onto the fuel injector (s).




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






Important: DO NOT lubricate the NEW seal.

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




6. Pull the NEW seal by hand over the EN 48266-1 and into the groove in the injector.
7. Remove the EN 48266-1 from the injector tip.




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




9. 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.
10. Remove the EN 48266-2.




11. Install the direct fuel injectors to the cylinder head.




12. Install the NEW direct fuel injector hold down clamps.




13. Place the fuel rail (2) into position.
14. Install the 2 outer fuel rail bolts (1) first, hand tight and install the remaining 2 bolts, hand tight.
15. Connect the fuel injector wiring harness electrical connectors (2) to the fuel injectors.




16. Tighten the fuel rail bolts in the sequence shown.

* Tighten the bolts a first pass to 22 N.m (16 lb ft).
* Tighten the bolts a final pass to 22 N.m (16 lb ft).




17. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
18. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
19. Install the NEW high pressure fuel pipe.
20. Tighten the NEW high pressure fuel pipe fitting to the fuel rail hand tight.
21. Tighten the NEW high pressure fuel pipe fitting to the fuel pump hand tight.

Tighten the fittings to 32 N.m (24 lb ft).




22. Install the high pressure fuel pump insulator.




23. Install the high pressure fuel pump cover.
24. Install the high pressure fuel pump cover bolts.

Tighten the bolts to 10 N.m (89 lb in).




25. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
26. Install the engine wiring harness clip (3) to the high pressure fuel pump cover.




27. Install the fuel injector insulator.
28. Install the intake manifold.




29. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
30. Inspect for leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition, for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.

31. Install the low side fuel pressure service port cap.
32. Tighten the fuel fill cap.
33. Install the intake manifold cover.