Fuel Injector: Service and Repair

Fuel Injector and Fuel Rail Replacement

Special Tools

EN-47909 - Fuel Injector Bore and Sleeve Cleaning Kit

For equivalent regional tools, refer to Special Tools (Tools and Equipment).

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Service and Repair).
2. Remove the fuel pipe shield. Refer to Fuel Pipe Shield Replacement (Fuel Pipe Shield Replacement).
3. Remove the intake manifold. Refer to Intake Manifold Replacement (Intake Manifold Replacement).
4. Remove the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement (Fuel Feed Intermediate Pipe Replacement).
5. Remove the foam insulator from the fuel rails.
6. Remove the cylinder head. Refer to Cylinder Head Replacement - Left Side (LF1 or LFW) (Cylinder Head Replacement - Left Side) or Cylinder Head Replacement - Right Side (LF1 or LFW) (Cylinder Head Replacement - Right Side)




7. Remove the bolts (1) from the bank 2 fuel rail.
8. Remove the bank 1 fuel rail and injectors (1) as an assembly. Refer to Cylinder Head Disassemble (LF1 or LFW) (55. Cylinder Head Disassemble).
9. Disconnect the bank 1 fuel injector electrical connections.




10. If the bank 2 fuel rail or injectors are being serviced, remove them. Refer to Cylinder Head Disassemble (LF1 or LFW) (55. Cylinder Head Disassemble).
11. Disconnect the bank 2 fuel injector and fuel pressure sensor electrical connections.

Note: The direct fuel injectors must be rebuilt whenever the injector has been released from the fuel rail or cylinder head.

12. It is necessary to rebuild the fuel injectors. Refer to Fuel Rail and Injectors Cleaning and Inspection (LF1 or LFW) (59. Fuel Rail and Injectors Cleaning and Inspection).

Installation Procedure




1. Clean the fuel injector bores using EN-47909 - kit.
2. Ensure that the fuel injectors have been properly rebuilt and lubricated. Refer to Fuel Rail and Injectors Cleaning and Inspection (LF1 or LFW) (59. Fuel Rail and Injectors Cleaning and Inspection).
3. Connect the bank 2 fuel injector and fuel pressure sensor electrical connections.
4. Position the bank 2 fuel rail and evenly hand tighten the 2 outer fuel rail bolts to seat the injectors into the injector bores. Remove the bolts.
5. Connect the bank 1 fuel injector electrical connections.
6. Position the bank 1 fuel rail and evenly hand tighten the 2 outer fuel rail bolts to seat the injectors into the injector bores.
7. Start and hand tighten the remaining fuel rail bolts.

Caution: Refer to Fastener Caution (Fastener Caution).

8. Tighten the bank 1 and bank 2 fuel rail bolts.

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

9. Replace any wire harness tie straps cut from the fuel rails.
10. Install the cylinder head. Refer to Cylinder Head Replacement - Left Side (LF1 or LFW) (Cylinder Head Replacement - Left Side) or Cylinder Head Replacement - Right Side (LF1 or LFW) (Cylinder Head Replacement - Right Side)
11. Install the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement (Fuel Feed Intermediate Pipe Replacement).
12. Inspect for fuel 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.

Note: Before installing the foam insulator, remove any remaining fuel from the injector well.

13. Install the foam insulator to the fuel rails.
14. Install the intake manifold. Refer to Intake Manifold Replacement (Intake Manifold Replacement).
15. Install the fuel pipe shield. Refer to Fuel Pipe Shield Replacement (Fuel Pipe Shield Replacement).
16. Install the low side fuel pressure service port cap.