Fuel Injector Replacement

Fuel Injector Replacement

Special Tools
* EN-47909 - Injector Bore and Sleeve Cleaning Kit
* EN-46594 - Fuel Injector Puller

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

Removal Procedure

1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (Engine Coolant Fan Upper Shroud Replacement).
2. Remove the exhaust gas recirculation bracket. Refer to Exhaust Gas Recirculation Valve Bracket Replacement (Exhaust Gas Recirculation Valve Bracket Replacement).





Caution: 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.

3. Disconnect the fuel injector electrical connectors (1).





Caution: 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.

4. Disconnect and reposition the fuel return pipes (1).





Note:
* Prior to removal of the fuel injector pipes, use compressed air to remove any debris from the injector line and fittings.
* Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist with removal.

5. Remove the fuel pipe bracket fasteners (1) and fuel injector pipes (2).




6. Remove the fuel injector bracket bolts (1).




7. Install EN-46954 - puller into the bolt hole in the fuel injector bracket.
8. Install a flare nut wrench onto EN-46954 - puller , and work the tool outward until the injector releases from its seat.
9. Remove the EN-46954 - puller.
10. Remove the fuel injectors (1) with brackets (2).
11. Remove and discard the copper washer from the fuel injector bore.
12. Remove and discard the fuel injector O-ring from the injector.

Fuel Injector Cleaning and Inspection





Note: 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.

Injector Bore Cleaning

Note: The procedure below will aid in the cleaning of carbon deposits from the injector sleeve during an injector replacement

1. Install the EN-47909-2 - brush to the EN-47909-1 - handle.
2. Insert the brush into the injector bore and rotate the handle in order to break loose any carbon deposits from the injector bore walls and the combustion deck hole.

Warning

Wear safety glasses in order to avoid eye damage.

3. Using compressed air, evacuate any debris from the injector bore.
4. Remove the radial brush from the handle assembly.
5. Install the EN-47909-3 - brush to the EN-47909-1 - handle.
6. Insert the axial brush into the injector bore and rotate the handle while also applying a slight downward pressure, in order to force the brush ends into the bottom corners of the injector bore.

Warning

Wear safety glasses in order to avoid eye damage.

7. Using compressed air, evacuate any debris from the injector bore.

Caution: Do not allow excessive amounts of solvent to go into the cylinder during cleaning. Failure to do so may cause engine damage upon start-up.

8. Lightly dampen EN-47909-20 - swab with Top Engine Cleaner, GM P/N 1052626 (Canadian P/N 993026) or equivalent, and wipe away any deposits from the injector bore.
9. Inspect the injector bore for any deposits and repeat brushing if necessary.

Warning

Keep hands and face clear of glow plug holes while cranking. Hot liquid or gases may be expelled during cranking.

Warning

Wear safety glasses in order to avoid eye damage.

10. If necessary, crank the engine in order to expel any solvent before starting the engine.

1. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 1 (Glow Plug Replacement - Bank 1) and/or Glow Plug Replacement - Bank 2 (Glow Plug Replacement - Bank 2).
2. Disable the fuel system.
3. Disconnect the crankshaft position (CKP) sensor electrical connector.
4. Crank the engine in order to expel any excessive solvent.
5. Using the cotton swabs supplied with the kit, wipe the injector bore clean of any solvent and/or debris.
6. Connect the CKP sensor electrical connector.
7. Enable the fuel system.
8. Reinstall the glow plugs. Refer to Glow Plug Replacement - Bank 1 (Glow Plug Replacement - Bank 1) and/or Glow Plug Replacement - Bank 2 (Glow Plug Replacement - Bank 2).

Installation Procedure




1. Install a NEW copper washer to the fuel injector bore.
2. Install a NEW fuel injector O-ring to the injector.
3. Install the fuel injectors (1) with brackets (2).





Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the fuel injector bracket fasteners (1) and tighten to 30 Nm (22 lb ft).





Caution: 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.

5. Install the left fuel injector pipes (2) and tighten to 30 Nm (22 lb ft).
6. Install the fuel pipe bracket fasteners (1) and tighten to 10 Nm(89 lb in).
7. 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.




8. Reposition and connect and the fuel return pipes (1).




9. Position the engine wiring harness, and install the engine wiring harness bracket fasteners (1) and tighten to 21 Nm (15 lb ft).
10. Install the exhaust gas recirculation bracket. Refer to Exhaust Gas Recirculation Valve Bracket Replacement (Exhaust Gas Recirculation Valve Bracket Replacement).
11. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (Engine Coolant Fan Upper Shroud Replacement).
12. If the fuel injectors were replaced, refer to Fuel Injector Flow Rate Programming (Procedures).
13. Prime the fuel system. Refer to Fuel System Priming (Fuel System Priming).
14. Start the engine. If the engine stalls, repeat the above step.
15. Once the engine starts, inspect for fuel leaks.