Buick Regal: Fuel Rail and Injectors Cleaning and Inspection

Special Tools

• EN-47909 Injector Bore and Sleeve Cleaning Kit
• EN-49245 Fuel Injector Seal Install/Sizer
• EN-50791 Fuel Injector Nozzle Installer
• EN-51105 Fuel Injector Seal Installer

For equivalent regional tools, refer to Special Tools.

1.

Remove and inspect the fuel rail insulator assemblies (1 - 4). Replace the entire assembly if any components show signs of wear or the insulators (4) show the following conditions:

• Dry or cracked appearance
• Flattened or misshapen appearance

2.

Disconnect the electrical connections from the fuel injectors.

3. Use EN-50791 installer (3) to compress the fuel injector (1), and relieve pressure on the retaining pin (2).

Remove the fuel injector retaining pin (2). Remove EN-50791 installer once the retaining pin is removed.

4.

NOTE:

• Support the fuel injector at the widest point. Support the fuel rail along the bottom.
• DO NOT support or hold the fuel injector by the tip or connector
• DO NOT tilt or excessively twist the injector during removal

Remove the injectors (1) from the fuel rail by pulling straight out along the fuel injector axis. Slight rotation of the fuel injector is acceptable as long as excessive force is not applied to the fuel injector tab while engaged in the fuel rail slot (3).

5. Remove the fuel injector holding clamp (2) from the rear of the fuel injector.

6.

Remove and discard the fuel injector O-ring (2) and plastic spacer (1).

7. Remove and discard the fuel injector seals (3).

8.

NOTE: Do not soak or submerge the fuel rail or injectors in solvent. Do not use solvent on the fuel rail label.

Clean the exterior of the fuel rail (1) and injectors in solvent.

9. Using EN-47909 cleaning kit, clean the fuel injector bores and sleeves.

10. 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

11. Replace the fuel rail if any damage is found. Do not attempt to repair a fuel rail.

CAUTION: Refer to Fastener Caution.

NOTE: Remove and inspect the fuel pressure sensor only if the sensor is suspect.

12. Inspect the fuel pressure sensor (3) for damage.

1. Disconnect the harness connector (2) from the fuel pressure sensor.
2. Remove the fuel pressure sensor. Dry the fuel pressure sensor bore in the fuel rail with a lint free cloth.

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

3. Lubricate the fuel rail fuel pressure sensor bore 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. Install the fuel pressure sensor and tighten to 33 N.m (25 lb ft).
8. Connect the harness connector to the fuel pressure sensor.

13.

Inspect the fuel injectors for the following conditions:

• Damage to the fuel injector connector (3)
• Damage to the fuel injector harness connector
• Damage to the fuel injector tip (5)
• Damage to the fuel injector (4)

14. Replace the fuel injector if any damage is found. Do not attempt to repair a fuel injector.

15. Install the a new fuel injector spacer (1).

16. Lubricate the NEW O-ring (2) with one drop of clean engine oil.

17. Install the O-ring on the injector.

18.

Install the fuel injector holding clamp (2) onto the rear of the fuel injector.

19. Hand install fuel injectors (1) to the fuel rail, carefully aligning the fuel injector tab to the slot in the fuel rail (3).

20.

NOTE: The injector must be fully installed and properly aligned with the fuel rail before installing the retaining pin.

Using EN-50791 installer (3), compress the fuel injector (1) into the fuel rail.

21. Ensure the fuel injector is fully seated in the fuel rail, and install the fuel injector retaining pin (4).

22. Ensure the fuel injector retaining pin is fully seated in the fuel rail. Remove EN-50791 installer. Repeat process until all fuel injectors are properly installed to the fuel rail.

23.

Connect the electrical connection to the fuel rail.

24. Connect the fuel rail harness connectors (1) to the fuel injectors.

25.

NOTE: Do not use any type of lubricant when installing the NEW seals on the fuel injector tip.

Install EN-51105-1 long protector (2) onto the fuel injector tip. Place a NEW seal (1) on EN-51105-1 long protector.

26. Using EN-49245 pusher, install the seal into the second recessed area (3) of the fuel injector, then remove the EN-51105-1 long protector.

27. Compress the seal with your fingers, then resize the seal using the EN-49245 sizer (4).

28. Install EN-51105-2 short protector (2) onto the fuel injector tip. Place a second NEW seal (1) on EN-51105-2 short protector.

29. Using EN-49245 pusher, install the seal into the remaining recessed area of the fuel injector, then remove EN- 51105-2 short protector.

30. Compress the seal with your fingers, then resize the seal using the EN-49245 sizer (4).

INTAKE MANIFOLD CLEANING AND INSPECTION

1.

Clean the intake manifold (1) mating surfaces.

2. Inspect the intake manifold for damage.

3. Inspect the intake manifold for cracks near metallic inserts.

4.

Inspect the crankcase ventilation passages (1) in the intake manifold face for blockage.

WARNING: Refer to Safety Glasses Warning.

5. Clean the crankcase ventilation passages with compressed air if necessary. Use a maximum of 172 kPa (25 psi) of air pressure.

6. Replace the intake manifold as necessary.

EXHAUST MANIFOLD CLEANING AND INSPECTION

1.

NOTE:

• Do not reuse the exhaust manifold-to-cylinder head gaskets. Upon installation of the exhaust manifold, install a NEW gasket. An improperly installed gasket or leaking exhaust system may effect On-Board Diagnostics (OBD) II system performance.
• Remove the oxygen sensor prior to cleaning the manifold. Do not submerge the oxygen sensor in cleaning solvent.

Remove the oxygen sensor (2) from the manifold.

2. Clean the exhaust manifold (1) in solvent.

WARNING: Refer to Safety Glasses Warning.

3. Dry the exhaust manifold with compressed air.

4. Inspect the exhaust manifold (1) for damage.

5. Inspect the heat shield (3) for damage.

6.

Use a straight edge and a feeler gauge and measure the exhaust manifold mounting face (1) for warpage.

An exhaust manifold face with warpage in excess of 0.25 mm (0.0100 in) may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.

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