Fuel Injector Replacement (Right)

FUEL INJECTOR REPLACEMENT (RIGHT)

TOOLS REQUIRED
J-46594 Fuel Injector Remover

REMOVAL PROCEDURE




1. Remove the air cleaner outlet duct.
2. Using a pick or a small flat-bladed screw driver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
3. Remove the charged air cooler outlet duct from the intake.
4. Remove the fuel filter and bracket.




5. Remove the wiring harness retainer from the bracket.
6. Remove the oil level indicator tube bolt.
7. Remove the oil level indicator tube bracket bolts.
8. Remove the bracket.




9. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
10. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
11. Remove the fuel injector pipes.

NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector.




12. Remove the fuel return hose clips.
13. Remove the fuel return hose from the injectors.




14. Disconnect the fuel injector electrical connectors.

NOTE: Label all the injector electrical connectors before the connectors are removed in order to prevent reconnecting to the wrong injector. Failure to properly connect the injectors in the correct sequence will cause severe engine damage.




15. Remove the fuel injector bracket bolts.




16. Install J-46594 into the bolt hole in the fuel injector bracket.
17. Install a flare nut wrench onto J-46594 and pull back away from the fuel injector, until the injector releases from its seat.
18. Remove J-46594.
19. Remove the fuel injectors with brackets.




20. If necessary, remove the fuel injector bracket pins.
21. If necessary, remove and discard the copper washer from the fuel injector bore.
22. If necessary, remove and discard the O-ring from the fuel injector.

FUEL INJECTOR CLEANING AND INSPECTION

IMPORTANT: If reusing the old injectors perform the following:




1. Use a soft bristle non-metallic brush and top engine cleaner, GM P/N 1052626 or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before re-installation.
2. Inspect the fuel injector nozzle tip (1) for any signs of discoloration (dark yellow, tan or blue) due to excessive heat.
3. Replace the injector if any damage is found.




4. Clean the fuel injector high pressure line.
5. Inspect the fuel injector line for excessive corrosion or damage to the sealing surfaces (1, 2). Replace the line if any damage is found.

INSTALLATION PROCEDURE




1. If necessary, install a NEW O-ring onto the fuel injector.
2. If necessary, install a NEW copper washer to the fuel injector bore.
3. If necessary, install the fuel injector bracket pins.




4. Install the fuel injectors with brackets.




5. Install the fuel injector bracket bolts.

NOTE: Refer to Fastener Notice.

Tighten the bolts to 30 N.m (22 lb ft).




6. Connect the fuel injector electrical connectors.




7. Install the fuel return hose to the injectors.
8. Install the fuel return hose clips.




9. Install the fuel injector pipes.

NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.

Tighten the fittings to 41 N.m (30 lb ft).

10. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.




11. Install the bracket.
12. Install the oil level indicator tube bracket bolts.

Tighten the bolts to 21 N.m (15 lb ft).

13. Install the oil level indicator tube bolt.

Tighten the bolt to 21 N.m (15 lb ft).

14. Install the wiring harness retainer to the bracket.
15. Install the fuel filter with bracket.




16. Install a NEW quick connect fitting clip to the charged air cooler duct.
17. Install the charged air cooler outlet duct to the intake.
18. Install the air cleaner outlet duct.
19. If the fuel injectors were replaced, refer to Fuel Injector Flow Rate Programming.
20. Prime the fuel system. Refer to Fuel System Priming.
21. Start the engine. If the engine stalls, repeat the above step.
22. Once the engine starts, inspect for fuel leaks.