47. Fuel Rail and Injectors Cleaning and Inspection

Fuel Rail and Injectors Cleaning and Inspection

Special Tools

EN-48266 - Injector Seal Installer and Sizer

For equivalent regional tools, refer to Special Tools (Special Tools)




1. Unplug the electrical connections from the fuel injectors (1).

Note: DO NOT tilt or twist the injector during removal.

2. Remove the injectors from the fuel rail by pulling straight out along the fuel injector axis.




3. Remove and discard the fuel injector hold-down clamp (3).
4. Remove and discard the fuel injector O-ring (2) and plastic spacer (1).




5. Remove and discard the fuel injector seal (1).





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

6. Clean the exterior of the fuel rail (2) and injectors in solvent.

Caution: Refer to Fastener Caution (Fastener Caution).

7. Inspect the high pressure fuel sensor (1) for damage.

1. If replacing, dry the fuel pressure sensor bore in the fuel rail with a lint free cloth.
2. The bore should be free of fuel, debris, and burrs.
3. Lubricate the fuel pressure sensor bore, in the fuel rail, 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. Re-install the fuel pressure sensor and tighten to 33 Nm (25 lb ft).

8. 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




9. Inspect the fuel injectors for the following conditions:

* Damage to the fuel injector connector (7)
* Damage to the fuel injector harness connector
* Damage to the fuel injector tip (1)
* Damage to the tolerance ring (2)
* Damage to the wave guide (3), if equipped

10. Replace the fuel rail or injector if any damage is found. Do not attempt to repair a fuel rail or injector.
11. Lubricate the NEW O-ring (5) with 5W30 engine oil.
12. Install a NEW O-ring and plastic spacer (4) on the injector. The plastic spacer has a top (6) and a bottom. The top, O-ring sealing area, is wider.





Note: Do not use any type of lubricant when installing the NEW seal (1) on the fuel injector tip.

13. Install EN-48266 - installer (2) onto the fuel injector tip. Install a NEW seal (1) over EN-48266 - installer on the injector. The seal must be installed/slid into the recessed area (3) of the fuel injector. Compress the seal with your fingers before resizing the seal using the EN-48266 - sizer.
14. Using the EN-48266 - sizer (4), resize the seal.




15. Install a NEW fuel injector hold-down clamp (2) on the fuel injector (1).
16. Repeat the fuel injector cleaning and inspection process for all 4 fuel injectors.





Note: DO NOT tilt or twist the injector during installation.

17. Install the fuel injectors (1) by pushing the injectors straight into the fuel rail along the fuel injector axis.
18. Connect the electrical connection to the fuel rail for each injector.