GM 12594512
Injector

Taking care when replacing a Fuel Injector will protect its electrical connector pins and nozzles from damage. Refrain from submerging fuel injectors in cleaning agents since this could cause harm. Fuel injectors from the 5.3l (L59) e85 application by denso lack o-ring and retaining clip independence for service therefore requiring a complete replacement of the Fuel Injector when either component suffers failure. Be mindful that leaking fuel injectors lead to contamination of the engine oil. Start by removing the Fuel Rail followed by removing both Fuel Injector retainer clip and the Fuel Injector . The machine should discard both the Fuel Injector retainer clip and the Fuel Injector O-Ring seals (2, 4). Check that your selected new fuel injectors match the requirements of the vehicle application you need them for. Each new Fuel Injector receives two markings from the manufacturer showing its unique part number and its production month , day and year along with production shift . Clean engine oil should be used to lubricate new Fuel Injector O-Ring seals (2, 4) before installing them onto the Fuel Injector. Insert the Fuel Injector into the Fuel Rail injector socket so that the electrical connector faces outward while inserting the retainer clip onto a flange on the Fuel Rail injector socket. Finally, reinstall the Fuel Rail.

The Fuel Injector replacement process starts by properly removing the air cleaner outlet duct then using ch-48027 or without it when relieving fuel system pressure. You need to disconnect ranges of engine wiring harness electrical connectors off components including evap purge solenoid, generator, map sensor and Ignition Coil and fuel injectors while you need to mark the connectors for correct future placement. The engine wiring harness clips and negative charge lead need to be detached from the right cylinder head position. First disconnect the quick connect fitting that feeds fuel to the chassis from its location on the Fuel Rail and also release the quick connect fittings at the intake manifold for the evap tube then at the evap canister purge solenoid. After unhinging the retainer holding the evap canister purge solenoid to the Fuel Rail you can extract the Fuel Rail assembly bolts while lifting the rail assembly carefully to prevent damage to the electrical connector terminals and spray tips. Begin the procedure by cleaning the Fuel Rail followed by removing the Fuel Injector retainers and lift out the injectors after disposing the old o-ring seals. Start by applying engine oil to new o-ring seals before installing them to injectors followed by inserting the injectors into the Fuel Rail. Position the Fuel Rail properly onto the intake manifold while keeping the retainers in place. Push down on the rail to achieve complete seating. After fitting the Fuel Rail bolts at 10 nm (89 lb in) tightness connect the evap tube and purge solenoid as well as the chassis fuel feed pipe quick connect fitting. Next position the pcv hose then gather the engine wiring harness before fixing it into position with its clips. The negative Battery Cable needs to be reconnected when all electrical connectors are tightened in place and engine wiring harness brackets receive a 5 nm (44 lb in) torque setting. Complete the check for leaks by turning the ignition on before reinstalling the air cleaner outlet duct.

The air cleaner outlet duct must be removed carefully before the replacement can start. Begin the fuel system pressure relief operation with ch-48027 or perform it without the tool then remove the engine wiring harness bracket nut. Next disconnect the electrical connectors from the evap purge solenoid, generator, map sensor, ignition coil main electrical connector and the fuel injectors. First mark each connector for later assembly before you move the cpa retainer with one click and press the tab to disconnect the Fuel Injector electrical connectors. Above the electronic throttle control device and Fuel Injector suite disconnect the electrical connectors while using the standard marking procedures. Uninstall those engine wiring harness clips which support the generator battery jumper cable and ignition coil bracket stud . Remove negative battery cable stud and terminals (2 and 3) from the Cylinder Head. First disconnect the wiring harness clip bolt from the generator bracket then place the harness aside while also removing the chassis fuel feed pipe quick connect fitting from the Fuel Rail. Lift out the evap purge solenoid from its position on the Fuel Rail by removing the bolts after unhitching evap tube fasteners at both the intake manifold and evap purge solenoid. Detach the Fuel Rail assembly while taking care not to harm either the injector electrical connector terminals or spray tips and apply caps over each fitting to stop any contamination. Evacuate all injectors from their bores while lifting the Fuel Rail in an even manner after cleaning it as needed. The installation of fuel injectors requires removing their retainers in combination with injectors and discarding the o-ring seals that sit at positions 2 and 4. First clean the engine oil to lubricate the new o-ring seals before attaching them to the injectors and installing the injectors into the Fuel Rail with retainers in place. After applying lubrication to the lower o-ring seals install the Fuel Rail onto the intake manifold while applying firm downward pressure until it reaches a complete position. First tighten 10 nm (89 lb in) Fuel Rail bolts before reinstalling the evap tube along with purge solenoid and making quick connect fittings to the evap canister and intake manifold. First reattach the Fuel Rail to the chassis feed pipe. After that, install the pcv hose before gathering all engine wiring harnesses over the engine. Take the generator bracket as the installation site for the wiring harness clip while tightening its clip bolt to 9 nm (80 lb in). Reinstall the negative battery cable stud on the right Cylinder Head unit while fastening it with 25 nm torque setting (18 lb ft). One should first reconnect the ignition coil main electrical connector then install the cpa retainer. Seed the electronic throttle control and Fuel Injector electrical connectors before tightening the cpa retainer. Fasten the engine wiring harness bracket nut with 5 nm (44 lb in) torque. After that, connect the MAP Sensor , generator and evap purge solenoid connectors followed by engine harness bracket assembly. Turn the ignition to on then off starting with two seconds of on time followed by ten seconds of off time before repeating the on step to check for any fluid leakage. Inspect for any leaks. Reinstall the air cleaner outlet duct at the end of the installation procedure.

Install the fuel injector into the fuel meter body injector socket.

Lubricate the NEW injector O-ring seals with clean engine oil.

Reconnect the negative battery cable, inspect for leaks by turning the ignition ON and OFF, and reinstall the air cleaner outlet duct.