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Fuel Rail and Injectors Cleaning and Inspection (LDK, LHU)

Fuel Rail and Injectors Cleaning and Inspection (LDK, LHU)


Special Tools

EN-48266 Injector Seal Installer and Sizer

For equivalent regional tools, refer to Special Tools (LDK, LHU) .



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


2.
Note

DO NOT tilt or twist the injector during removal.


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).


6.
Note

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


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


7. Refer to Fastener Caution .

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

7.1. If replacing, dry the fuel pressure sensor bore in the fuel rail with a lint free cloth.

7.2. The bore should be free of fuel, debris, and burrs.

7.3. Lubricate the fuel pressure sensor bore, in the fuel rail, with clean engine oil.

7.4. Lubricate the threads and sealing area on the fuel pressure sensor with clean engine oil.

7.5. Install the fuel pressure sensor hand tight.

7.6. Remove the fuel pressure sensor and re-lubricate the bore, threads, and sealing area.

7.7. Re-install the fuel pressure sensor. Tighten the high pressure fuel sensor 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.

13.
Note

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


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.

17.
Note

DO NOT tilt or twist the injector during installation.


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.