Solstice 2006-2008, Sky 2007-2008

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.0L (LNF) Engine

CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


CAUTION
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the engine wiring harness electrical connector from the fuel injector wiring harness electrical connector.
  4.  
  5. Remove the intake manifold.
  6.  
  7. Remove the fuel injector insulator.
  8.  
  9. Relieve the high side fuel system pressure.
  10.  
  11. Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
  12.  
  13. Remove the high pressure fuel pump cover bolts.
  14.  
  15. Remove the high pressure fuel pump cover.
  16.  
  17. Remove the engine wiring harness clip from the high pressure fuel pump cover.
  18.  
  19. Remove the high pressure fuel pump insulator.
  20.  
  21. Loosen the high pressure fuel pipe fitting at the fuel pump.
  22.  
  23. Loosen the high pressure fuel pipe fitting at the fuel rail.
  24.  
  25. Remove and discard the high pressure fuel pipe.
  26.  
  27. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  28.  
  29. Remove the fuel rail bolts.
  30.  
  31. Carefully remove the fuel rail.
    NOTE
    The fuel injectors may come out of the cylinder head with the fuel rail.

  32.  
  33. Remove and discard the direct fuel injector hold down clamps.
  34.  
  35. Remove the direct fuel injectors.

    Click image to see an enlarged view

    Fig. Direct fuel injector removal 2.0L (LNF) engine

  36.  
  37. If necessary, use a slide hammer and the J-37281-A injector removal adapter in order to remove the direct fuel injectors.
  38.  
  39. Remove and discard the upper O-ring seal and plastic spacer from the injector.
  40.  
  41. Carefully remove and discard the lower nylon seal from the injector.

    Click image to see an enlarged view

    Fig. Direct fuel injector view

  42.  

To install:

  1. Install a new plastic spacer onto the fuel injector.
  2.  
  3. Lubricate a new O-ring seal with silicon free engine oil
  4.  
  5. Carefully install the new O-ring seal onto the fuel injector.
  6.  
  7. From the EN-48266 , position the EN 48266-1 to the injector tip.
  8.  
  9. Install a new seal onto the EN 48266-1.

    Click image to see an enlarged view

    Fig. Fuel injector with EN 48266-1 tool and O-ring

  10.  
  11. Pull the new seal by hand over the EN 48266-1 and into the groove in the injector.
  12.  
  13. Remove the EN 48266-1 from the injector tip.
  14.  
  15. From the EN-48266, install the EN 48266-2 to the injector tip.

    Click image to see an enlarged view

    Fig. Fuel injector with EN 48266-2 tool installed

  16.  
  17. Using the EN 48266-2, resize the seal. Install the EN 48266-2, until it bottoms out against the injector body, and rotate the EN 48266-2 while applying only moderate force 180 degrees in one direction and then 180 degrees back in the other direction.
  18.  
  19. Remove the EN 48266-2.
  20.  
  21. Install the direct fuel injectors to the cylinder head.
  22.  
  23. Install the new direct fuel injector hold down clamps.
  24.  
  25. Place the fuel rail into position.
  26.  
  27. Install the outer fuel rail bolts first, hand tight and install the remaining bolts, hand tight.
  28.  
  29. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
  30.  
  31. Tighten the fuel rail bolts in the sequence shown to:
    1. Tighten the bolts a first pass to 16 ft. lbs. (22 Nm).
    2.  
    3. Tighten the bolts a final pass to 16 ft. lbs. (22 Nm).

      Click image to see an enlarged view

      Fig. Fuel rail tightening sequence 2.0L (LNF) engine

    4.  

  32.  
  33. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  34.  
  35. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil
  36.  
  37. Install the new high pressure fuel pipe.
  38.  
  39. Tighten the new high pressure fuel pipe fitting to the fuel rail hand tight.
  40.  
  41. Tighten the new high pressure fuel pipe fitting to the fuel pump hand tight.
  42.  
  43. Tighten the fittings to 24 ft. lbs. (32 Nm).
  44.  
  45. Install the high pressure fuel pump insulator.
  46.  
  47. Install the high pressure fuel pump cover.
  48.  
  49. Install the high pressure fuel pump cover bolts and tighten to 89 inch lbs. (10 Nm).
  50.  
  51. Connect the engine wiring harness electrical connector to the high pressure fuel pump
  52.  
  53. Install the engine wiring harness clip (3) to the high pressure fuel pump cover.
  54.  
  55. Install the fuel injector insulator.
  56.  
  57. Install the intake manifold.
  58.  
  59. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
  60.  
  61. Inspect for leaks using the following procedure:

    Turn ON the ignition, with the engine OFF for 2 seconds.
     
    Turn OFF the ignition, for 10 seconds.
     
    Turn ON the ignition, with the engine OFF.
     
    Inspect for fuel leaks.
     

  62.  
  63. Install the low side fuel pressure service port cap.
  64.  
  65. Tighten the fuel fill cap.
  66.  
  67. Install the intake manifold cover.
  68.  

2.4L (LE5) Engine

CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


CAUTION
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Disconnect the fuel injector inline electrical connector.
  8.  
  9. Disconnect the electronic throttle control (ETC) electrical connector.
  10.  
  11. Remove the 2 engine harness clips from the fuel rail tabs.
  12.  
  13. Remove the fuel rail bolts.
    NOTE
    Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips.

  14.  
  15. Pull the fuel rail back and upward in order to release the fuel injectors from the cylinder head ports.
  16.  
  17. Remove the fuel rail.
    WARNING
    Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.


    NOTE
    If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel.



    Click image to see an enlarged view

    Fig. Fuel rail



    Click image to see an enlarged view

    Fig. Fuel injector components

  18.  
  19. Remove the fuel injector retaining clip.
  20.  
  21. Remove the fuel injector from the fuel rail.
  22.  
  23. Remove the fuel injector upper O-ring.
  24.  
  25. Remove the fuel injector lower O-ring.
  26.  

To install:


NOTE
Be sure to use the correct part number when ordering replacement fuel injectors.

  1. The fuel injector assembly is stamped with a part number identification.
  2.  
  3. Lubricate the new injector O-rings with clean engine oil.
  4.  
  5. Install the fuel injector upper O-ring.
  6.  
  7. Install the fuel injector lower O-ring.
  8.  
  9. Install the fuel injector to the fuel rail.
  10.  
  11. Install the fuel injector retaining clip.
    NOTE
    Install NEW lower O-rings when reusing fuel injectors. Lubricate the lower O-rings prior to installing the injectors into the intake manifold.

  12.  
  13. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  14.  
  15. Carefully push the fuel injectors into the cylinder head ports.
  16.  
  17. Install the fuel rail bolts. Tighten the bolts to 10 Nm (89 inch lbs.).
  18.  
  19. Install the 2 engine harness clips to the fuel rail tabs.
  20.  
  21. Connect the ETC electrical connector.
  22.  
  23. Connect the fuel injector inline electrical connector.
  24.  
  25. Install the air cleaner outlet duct.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Inspect for fuel leaks using the following procedure:

    Turn ON the ignition, with the engine OFF for 2 seconds.
     
    Turn OFF the ignition for 10 seconds.
     
    Turn ON the ignition.
     
    Inspect for fuel leaks.
     

  30.  

 
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