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Fuel Injector Replacement

Special Tools

Equivalent regional tools: Special Tools

CAUTION: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.
  1. Fuel Injection Fuel Rail» Remove - Fuel Injection Fuel Rail Assembly Replacement 
  2. Remove and inspect the fuel rail insulator assemblies (1-4). Replace the entire assembly if any components show signs of wear or the insulators (4) show the following conditions:
    Fig 1: Fuel Rail Insulator Assemblies
    GM2836381Courtesy of GENERAL MOTORS COMPANY
    • Dry or cracked appearance
    • Flattened or misshapen appearance
  3. Disconnect the electrical connectors from the fuel injectors.
    Fig 2: Fuel Injector And Retaining Pin
    GM2742603Courtesy of GENERAL MOTORS COMPANY
  4. Use the EN-50791  installer (3) to compress the fuel injector (1) and relieve pressure on the retaining pin (2). Remove the fuel injector retaining pin (2). Remove the EN-50791  installer once the retaining pin is removed.
  5. Remove the fuel injectors (1) from the fuel injection fuel rail by pulling it straight out along the fuel injector axis. Slight rotation of the fuel injector is acceptable as long as excessive force is not applied to the fuel injector tab while engaged in the fuel rail slot (3).
    Fig 3: Injectors And Fuel Rail Slot
    GM2742599Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Support the fuel injector at the widest point.
    • Support the fuel injection fuel rail along the bottom.
    • Do NOT support or hold the fuel injector by the tip or connector.
    • Do NOT tilt or excessively twist the fuel injector during removal.
  6. Remove the fuel injector holding clamp (2) from the rear of the fuel injector.
  7. Remove and DISCARD the fuel injector O-ring (2) and spacer (1).
    Fig 4: Fuel Injector O-Ring And Plastic Spacer
    GM2742600Courtesy of GENERAL MOTORS COMPANY
  8. Remove and DISCARD the fuel injector seals (3).
  9. Clean the exterior of the fuel injection fuel rail (1) and fuel injectors in solvent.
    Fig 5: Fuel Rail
    GM2742601Courtesy of GENERAL MOTORS COMPANY
    NOTE: Do NOT soak or submerge the fuel injection fuel rail or fuel injectors in solvent. Do NOT use solvent on the fuel rail label.
  10. Use the EN-47909  cleaning kit to clean the fuel injector bores and sleeves.
  11. Inspect the fuel injection fuel rail and components for the following conditions:
    • Damage, debris or restrictions to the fuel rail
    • Damage, debris or restrictions to the fuel ports in the fuel rail
    • Damage to the mounting area for the fuel rail
    • Damage to the fuel rail mounting bolts
    • Damage to the threads on the fuel rail fuel feed fitting
  12. Replace the fuel injection fuel rail if ANY damage is found. Do NOT attempt to repair a fuel rail.
  13. Remove and inspect the fuel injection fuel rail pressure sensor (3) for damage using the following procedure:
    CAUTION: Refer to Fastener Caution .
    NOTE: Remove and inspect the fuel injection fuel rail pressure sensor ONLY if the sensor is suspect.
    1. Disconnect the wiring harness connector from the fuel injection fuel rail pressure sensor.
    2. Remove the fuel injection fuel rail pressure sensor. Dry the pressure sensor bore in the fuel rail with a lint free cloth. The bore should be free of fuel, debris and burrs.
    3. Lubricate the fuel injection fuel rail fuel pressure sensor bore with clean engine oil.
    4. Lubricate the threads and sealing area on the fuel injection fuel rail fuel pressure sensor with clean engine oil.
    5. Install the fuel injection fuel rail fuel pressure sensor hand tight.
    6. Remove the fuel injection fuel rail fuel pressure sensor and re-lubricate the bore, threads and sealing area.
    7. Install the fuel injection fuel rail fuel pressure sensor and tighten to 33 N.m (24 lb ft).
    8. Connect the wiring harness connector to the fuel injection fuel rail fuel pressure sensor.
  14. Inspect the fuel injectors for the following conditions:
    Fig 6: Fuel Injector Connector
    GM2742602Courtesy of GENERAL MOTORS COMPANY
    • Damage to the fuel injector connector (3)
    • Damage to the fuel injector harness connector
    • Damage to the fuel injector tip (5)
    • Damage to the fuel injector (4)
  15. Replace the fuel injector if ANY damage is found. Do NOT attempt to repair a fuel injector.
  16. Install the NEW fuel injector spacer (1).
  17. Install the NEW fuel injector O-ring.
    NOTE: Lubricate the NEW O-ring with clean engine oil.
  18. Install the fuel injector holding clamp (2) onto the rear of the fuel injector.
    Fig 7: Injectors And Fuel Rail Slot
    GM2742599Courtesy of GENERAL MOTORS COMPANY
  19. Hand install the fuel injector (1) to the fuel injection fuel rail, carefully aligning the fuel injector tab to the slot in the fuel rail (3).
  20. Use the EN-50791  installer (3) to compress the fuel injector (1) into the fuel injection fuel rail.
    Fig 8: Fuel Injector And Retaining Pin
    GM2742603Courtesy of GENERAL MOTORS COMPANY
    NOTE: The fuel injector MUST be fully installed and properly aligned with the fuel injection fuel rail before installing the retaining pin.
  21. Ensure the fuel injector is fully seated in the fuel injection fuel rail and install the fuel injector retaining pin (4).
  22. Ensure the fuel injector retaining pin is fully seated in the fuel injector fuel rail and remove EN-50791  installer.
  23. Repeat the process until all fuel injectors are properly installed to the fuel rail.
  24. Connect the electrical connectors (1) to the fuel injectors.
    Fig 9: Fuel Rail Harness Connectors
    GM2742605Courtesy of GENERAL MOTORS COMPANY
  25. Install the EN-51105-1  long protector (2) onto the fuel injector tip.
    Fig 10: Second Recessed Area And NEW Seal
    GM2742606Courtesy of GENERAL MOTORS COMPANY
    NOTE: Do NOT use any type of lubricant when installing the NEW fuel injector seals on the fuel injector tip.
  26. Place a NEW fuel injector seal (1) onto the EN-51105-1  long protector.
  27. Use the EN-49245  pusher to install the NEW fuel injector seal into the second recessed area (3) of the fuel injector.
  28. Remove the EN-51105-1  long protector.
  29. Compress the NEW fuel injector seal with your fingers, then resize the seal using the EN-49245  pusher (4).
  30. Install the EN-51105-2  short protector (2) onto the fuel injector tip.
    NOTE: Do NOT use any type of lubricant when installing the NEW fuel injector seals on the fuel injector tip.
  31. Place a NEW fuel injector seal (1) onto the EN-51105-2  short protector.
  32. Use the EN-49245  pusher to install the NEW fuel injector seal into the remaining recessed area of the fuel injector.
  33. Remove the EN-51105-2  short protector.
  34. Compress the NEW fuel injector seal with your fingers, then resize the seal using the EN-49245  pusher (4).
  35. Fuel Injection Fuel Rail» Install - Fuel Injection Fuel Rail Assembly Replacement 
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