Fuel Injector: Service and Repair
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 (Diagnostic Tools) Special Tools (Diagnostic Tools)
Removal Procedure
1. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.
Note: 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 (LF1, LFW) Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LF1, LFW) or Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LF1, LFW) 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
Note: Lubricate a NEW O-ring seal (1) with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Computers and Control Systems.
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 - installer , position the EN 48266-1 to the injector tip.
Note: DO NOT lubricate the NEW teflon seal.
3. 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 the 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).
Note: The fuel injectors have an alignment feature and must be reinstalled as noted during removal.
10. Install the fuel injection fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LF1, LFW) Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LF1, LFW) or Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LF1, LFW) Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LF1, LFW).