Fuel Injector and Fuel Rail Replacement

Fuel Injector and Fuel Rail Replacement (LP1, LY7)

Removal Procedure
Warning: Refer to Gasoline/Gasoline Vapors Warning (Service Precautions).


1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (High Pressure Pump - LLT) (Fuel Pressure Relief (High Pressure Pump))Fuel Pressure Relief (CH 48027 - LP1, LY7) (Fuel Pressure Relief (CH 48027))Fuel Pressure Relief (Without CH 48027 - LY7) (Fuel Pressure Relief (Without CH 48027)).
2. Remove the upper intake manifold with the lower intake manifold. Refer to Upper Intake Manifold Replacement (LP1, LY7) (Upper Intake Manifold Replacement).




3. Remove the fuel pipe retaining clip.




4. Disconnect the fuel feed pipe (2) from the fuel injector rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
Warning: Refer to Safety Glasses and Compressed Air Warning (Safety Glasses and Compressed Air Warning).

5. Use compressed air in order to remove debris from the area where the fuel injectors enter the intake manifold.




6. Remove the fuel rail bolts.

Caution:
* Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
* Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

7. Remove the fuel rail with the fuel injectors.




8. Disengage the fuel injector electrical connector lock.




9. Disconnect the fuel injector electrical connector.




10. Remove the fuel injector retainer clip.




11. Remove the fuel injector.
12. Remove and discard the fuel injector seals.

Installation Procedure

1. Install NEW fuel injector seals.




2. Install the fuel injector.




3. Install the fuel injector retainer clip.




4. Install the fuel injector electrical connector.
5. Engage the fuel injector electrical connector lock.




6. Install the fuel rail with the fuel injectors.

Caution: Refer to Fastener Caution (Fastener Caution).

7. Install the fuel rail bolts.

Tighten the fuel rail bolts to 10 Nm (89 lb in).




8. Connect the fuel feed pipe (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




9. Install the fuel pipe retaining clip.
10. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement (LP1, LY7) (Upper Intake Manifold Replacement).