Fuel Injector Replacement Right

Tools Required

1. Remove the engine cover. Refer to Engine Cover Replacement .
2. Remove the glow plug control module. Refer to Glow Plug Control Module Replacement .
3. Remove the air cleaner . Refer to Air Cleaner Replacement .
4. Remove the charged air cooler outlet from the intake. Refer to Charged Air Cooler Hoses/Pipes Replacement .
5. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
6. Remove the fuel injector pipes.



7. Remove the fuel return hose clips.
8. Remove the fuel return hose from the injectors.



9. Disconnect the fuel injector electrical connectors.



10. Remove the fuel injector bracket bolts.



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



15. If necessary, remove the fuel injector bracket pins.
16. Remove and discard the copper washer from the fuel injector bore.
17. Remove and discard the O-ring from the fuel injector.

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.

Important: 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 Radial Brush (brass), to the EN-47909-1 Handle Assembly.
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.

Caution: 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 Axial Brush (nylon), to the EN-47909-1.
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.

Caution: Wear safety glasses in order to avoid eye damage.

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

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

8. Lightly dampen EN-47909-20 Cotton 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.

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

Caution: 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.

10.1.

Remove the glow plugs. Refer to Glow Plug Replacement - Bank 1 and/or Glow Plug Replacement - Bank 2 .

10.2.

Disable the fuel system.

10.3.

Disconnect the crankshaft position (CKP) sensor electrical connector.

10.4.

Crank the engine in order to expel any excessive solvent.

10.5.

Using the cotton swabs supplied with the kit, wipe the injector bore clean of any solvent and/or debris.

10.6.

Connect the CKP sensor electrical connector.

10.7.

Enable the fuel system.

10.8.

Reinstall the glow plugs. Refer to Glow Plug Replacement - Bank 1 and/or Glow Plug Replacement - Bank 2 .

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



4. Install the fuel injectors with brackets.

Notice: Refer to Fastener Notice in the Preface section.




5. Install the fuel injector bracket bolts.

Tighten
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.

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

10. Install the glow plug control module. Refer to Glow Plug Control Module Replacement .

Important: Lubricate the end of the duct prior to installation.

11. Install the charged air cooler outlet to the intake. Refer to Charged Air Cooler Hoses/Pipes Replacement .
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
13. Install the air cleaner . Refer to Air Cleaner Replacement .
14. Install the engine cover. Refer to Engine Cover Replacement .
15. If the fuel injectors were replaced, Refer to Fuel Injector Flow Rate Programming .
16. Prime the fuel system. Refer to Fuel System Priming .
17. Start the engine. If the engine stalls, repeat the above step.
18. Once the engine starts, inspect for fuel leaks.