• Fuel Injection Fuel Rail Seal
• Fuel Injector Bushing
• Fuel Injector Retainer
• Fuel Injector Seal
• Fuel Injector Seal Spacer-Brown
• Fuel Injector Seal Spacer-White

• EN-47909 Injector Bore and Sleeve Cleaning Kit
• EN-49245 Injector Seal Installer Kit
• EN-49247 Injector Retaining Clip Installer

For equivalent regional tools, refer to Special Tools.

1. Detach and remove the fuel rail wiring harness (1) from the fuel injector rail.



2. Using a suitable tool remove the fuel injector to rail retainer (1) from the fuel injector rail by spreading both sides of the fuel injector to rail retainer at the same time.
3. DISCARD the fuel injector retainer (1).
4. Carefully twist the fuel injector to remove the fuel injector (2) from the fuel injector rail.



5. Using a suitable tool remove the fuel injector bushing (3).
6. DISCARD fuel injector bushing.
7. Remove and DISCARD the fuel injection fuel rail seal (1).
8. Remove and DISCARD the fuel injector seal spacers (2).
9. Remove and DISCARD the fuel injector seals (4).




Note: Do not apply force to the plastic housing of the fuel pressure sensor. Failure to comply will destroy the sensor.

10. Remove the fuel pressure sensor (1) from the fuel injector rail.

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

11. Clean the exterior of the fuel injector rail and fuel injectors with solvent using the injector bore and sleeve cleaning kit EN-47909 injector bore and sleeve cleaning kit.



12. Inspect the fuel injector rail (1) 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 or mounting bolt grommets/isolators
• Damage to the threads on the fuel rail feed fitting
• Damage to the threads in the fuel pressure sensor bore
• Damage to the fuel pressure sensor connector, threads, or sealing face
13. If any of the above conditions are found, replace the fuel injector rails. Do not attempt to repair the fuel injector rails.




Note: Do not apply force to the plastic housing of the fuel pressure sensor. Failure to comply will destroy the sensor.

14. Install the fuel pressure sensor (1) to the fuel injector rail.

Note: Ensure that the fuel rail threads have been cleaned of any excess fuel or the fuel pressure sensor will NOT seal properly.

1. Lubricate the threads and the sealing area in the fuel rail with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended lubricant.
2. Lubricate the threads and the sealing area on the fuel pressure sensor with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended lubricant.
3. Install the fuel pressure sensor to the fuel injector rail and hand tighten.
4. Remove the fuel pressure sensor from the fuel injector rail and re-lubricate.

Caution: Refer to Fastener Caution.

5. Install the fuel pressure sensor to the fuel injector rail and tighten to 33 N·m (25 lb ft).



15. Inspect the fuel injectors for the following conditions:
• Damage to the fuel injector connector (1)
• Damage to the fuel inlet cone (2)
• Damage to the fuel injector body (3)
• Damage to the fuel injector tip (4)
16. Replace the fuel injector if any of the above conditions are found. Do not attempt to repair the fuel injectors.




Note:

• The fuel injector bushing (1) is to be installed BEFORE seal or spacers are installed.
• Listen for an audible click to confirm correct installation of the fuel injector bushing

17. Install NEW fuel injector bushing (1) onto injector body. Bushing should seat with a distinct “snap” sound and feel. Ensure bushing is fully seated.



18. Install the NEW white plastic spacer (3) on the fuel injector first.
19. Install the brown plastic spacer (2) second.
20. Lubricate the NEW fuel injection fuel rail seal (1) with one drop of clean engine oil.




Caution: Ensure the fuel injectors are installed in the correct orientation. Improper orientation of the fuel injectors may result in engine misfire and possible engine damage.

21. The right side (bank 1) fuel injector wiring harness connectors (1) should point to the rear of the engine. The left side (bank 2) fuel injector wiring harness connectors (2) should point to the front of the engine.




Note:

• Do NOT install the Teflon injector tip/bore seals until AFTER the injectors are installed on the fuel rail.
• Make sure that the fuel injector connectors are placed in the correct position.

22. Holding the largest diameter/body of the injector only, indicated by arrow in graphic, insert the injector assembly (1) into the fuel rail. Ensure correct orientation of the electrical connector (2).
23. Clamp the fuel rail in a bench vise USING SOFT JAWS to aid in holding the rail during the installation of the retainer.



24. Support the fuel injector fuel rail in a vise.

Note: Ensure the retainer is set properly into EN-49247 installer.

• The notch (1) should always face forward
• The fuel injector to fuel rail retainer should be behind the plate (2)
• The tool windows (3) allow for visual alignment

25. Install the fuel injector to fuel rail retainer to the EN-49247 injector retaining clip installer.




Note: Observe the following steps before installing the fuel injector to fuel rail retainer.

26. There is a 15-degree angle of rotation (1) with the fuel injector rail flanges relative to the fuel injector rail. Hold the EN-49247 injector retaining clip installer at a similar angle to aid the correct installation of the fuel injector to fuel rail retainer.



27. When mounting the EN-49247 injector retaining clip installer to the fuel injector rail, the fuel injector to fuel rail retainer should nearly be touching the electrical connector (2).
28. The base of the EN-49247 injector retaining clip installer should be positioned as shown before squeezing the tool to complete the installation.



29. Hold the injector bushing (2) and fuel injector rail flanges (1) in alignment.
30. Hold the injector assembly firmly against the fuel injector rail to prevent a gap forming between the fuel injector and the fuel injector rail.
31. Install the fuel injector to fuel rail retainer (3).




Caution: Ensure the fuel injector retainer is properly installed. Failure to completely install the retainers may degrade fuel injection system performance or cause system malfunction.

32. Ensure all 3 fuel injector bushing tabs and fuel rail flanges (1) are properly and completely captured by the fuel injector retainer.
33. Repeat the above steps for the remaining fuel injectors until all the fuel injectors are installed and retained in the fuel injector rail.



34. Install the fuel injector rail wiring harness (1) to the fuel injector rail.




Note: Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector tip.

35. Install the long protector (3) of the EN-49245-1 fuel injector seal install/sizer to the fuel injector spray tip covering the first recessed area closest to the tip.
36. Place a NEW seal (2) onto long protector (3) of the EN-49245-1 fuel injector seal install/sizer.
37. Using the pusher (1) of the EN-49245-3 fuel injector seal install/sizer, push the seal (2) into the second recessed area (4) of the fuel injector.

Note: The sizer (5) of the EN-49245-4 fuel injector seal install/sizer is two sided, and either direction will size the seal correctly.

38. Compress the seal (2) with your fingers.
39. Resize the seal (2) using the sizer (5) of the EN-49245-4 fuel injector seal install/sizer.




Note: Do not use any type of lubricant when installing the NEW seals (2) on the fuel injector tip.

40. Install the short protector (3) of the EN-49245-2 fuel injector seal install/sizer to the fuel injector tip.
41. Place a NEW seal (2) onto the short protector (3) of EN-49245-2 fuel injector seal install/sizer.
42. Using the pusher (1) of the EN-49245-3 fuel injector seal install/sizer, push the seal (2) into the first recessed area (4) of the fuel injector.

Note: The sizer (5) of the EN-49245-4 fuel injector seal install/sizer is two sided, and either direction will size the seal correctly.

43. Compress the seal (2) with your fingers.
44. Resize the seal (2) using the sizer (5) of the EN-49245-4 fuel injector seal install/sizer.