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Fuel Rail and Injectors Cleaning and Inspection





Fuel Rail and Injectors Cleaning and Inspection

Special Tools

* EN-47909 - Injector Bore and Sleeve Cleaning Kit

* EN-48266 - Fuel Injector Seal Installer and Sizer

* EN-50791 - Fuel Injector Nozzle Installer

For equivalent regional tools, refer to Special Tools Special Tools.




1. 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:

* Dry or cracked appearance

* Flattened or misshapen appearance




2. Disconnect the electrical connections from the fuel injectors.

3. Use 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 EN-50791 - installer once the retaining pin is removed.





Note: Support the fuel injector at the widest point. Support the 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 injector during removal

4. Remove the injectors (1) from the fuel rail by pulling 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).

5. Remove the fuel injector holding clamp (2) from the rear of the fuel injector.




6. Remove and discard the fuel injector O-ring (2) and plastic spacer (1).

7. Remove and discard the fuel injector seals (3).





Note: Do not soak or submerge the fuel rail or injectors in solvent. Do not use solvent on the fuel rail label.

8. Clean the exterior of the fuel rail (1) and injectors in solvent.

9. Using EN-47909 - cleaning kit, clean the fuel injector bores and sleeves.

10. Inspect the 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

11. Replace the fuel rail if any damage is found. Do not attempt to repair a fuel rail.

Caution: Refer to Fastener Caution Fastener Caution.

Note: Remove and inspect the fuel pressure sensor only if the sensor is suspect.

12. Inspect the fuel pressure sensor (3) for damage.

1. Disconnect the harness connector (2) from the fuel pressure sensor.

2. Remove the fuel pressure sensor. Dry the fuel 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 rail fuel pressure sensor bore with clean engine oil.

4. Lubricate the threads and sealing area on the fuel pressure sensor with clean engine oil.

5. Install the fuel pressure sensor hand tight.

6. Remove the fuel pressure sensor and re-lubricate the bore, threads, and sealing area.

7. Install the fuel pressure sensor and tighten to 33 Nm (25 lb ft).

8. Connect the harness connector to the fuel pressure sensor.




13. Inspect the fuel injectors for the following conditions:

* 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)

14. Replace the fuel injector if any damage is found. Do not attempt to repair a fuel injector.

15. Install the a new fuel injector spacer (1).

16. Lubricate the new O-ring (2) with clean, silicone-free 5W30 engine oil.

17. Install the O-ring on the injector.




18. Install the fuel injector holding clamp (2) onto the rear of the fuel injector.

19. Hand install fuel injectors (1) to the fuel rail, carefully aligning the fuel injector tab to the slot in the fuel rail (3).





Note: The injector must be fully installed and properly aligned with the fuel rail before installing the retaining pin.

20. Using EN-50791 - installer (3), compress the fuel injector (1) into the fuel rail.

21. Ensure the fuel injector is fully seated in the fuel rail, and install the fuel injector retaining pin (4).

22. Ensure the fuel injector retaining pin is fully seated in the fuel rail. Remove EN-50791 - installer. Repeat process until all fuel injectors are properly installed to the fuel rail.




23. Connect the electrical connection to the fuel rail.

24. Connect the fuel rail harness connectors (1) to the fuel injectors.





Note: Do not use any type of lubricant when installing the NEW seals on the fuel injector tip.

25. Install EN-48266 - protector (2) onto the fuel injector tip. Place a NEW seal (1) on EN-48266 - protector.

26. Install a seal into the second recessed area (3) of the fuel injector.

27. Compress the seal with your fingers, then resize the seal using the EN-48266 - sizer (4).

28. Place a second NEW seal (1) on EN-48266 - protector.

29. Install the seal into the first recessed area of the fuel injector.

30. Compress the seal with your fingers, then resize the seal using the EN-48266 - sizer (4).

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