Captiva

Fuel Injector and Fuel Rail Replacement

Special Tools

EN-47909 Fuel Injector Bore and Sleeve Cleaning Kit

For equivalent regional tools, refer to Special Tools : Diagnostic Tools Diesel .

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Remove the fuel pipe shield. Refer to Fuel Pipe Shield Replacement : LF1 or LFW .
3. Remove the intake manifold. Refer to Inlet Manifold Replacement .
4. Remove the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement : LF1 or LFW .
5. Remove the foam insulator from the fuel rails.
6. Remove the cylinder head. Refer to Cylinder Head Replacement - Left Side or Cylinder Head Replacement - Right Side



7. Remove the bolts (1) from the bank 2 fuel rail.
8. Remove the bank 1 fuel rail and injectors (1) as an assembly. Refer to Cylinder Head Disassemble : LF1, LFW or LFX .
9. Disconnect the bank 1 fuel injector electrical connections.



10. If the bank 2 fuel rail or injectors are being serviced, remove them. Refer to Cylinder Head Disassemble : LF1, LFW or LFX .
11. Disconnect the bank 2 fuel injector and fuel pressure sensor electrical connections.

Note: The direct fuel injectors must be rebuilt whenever the injector has been released from the fuel rail or cylinder head.

12. It is necessary to rebuild the fuel injectors. Refer to Fuel Rail and Injectors Cleaning and Inspection : LF1, LFW or LFX .

1. Clean the fuel injector bores using EN-47909 kit .
2. Ensure that the fuel injectors have been properly rebuilt and lubricated. Refer to Fuel Rail and Injectors Cleaning and Inspection : LF1, LFW or LFX .
3. Connect the bank 2 fuel injector and fuel pressure sensor electrical connections.
4. Position the bank 2 fuel rail and evenly hand tighten the 2 outer fuel rail bolts to seat the injectors into the injector bores. Remove the bolts.
5. Connect the bank 1 fuel injector electrical connections.
6. Position the bank 1 fuel rail and evenly hand tighten the 2 outer fuel rail bolts to seat the injectors into the injector bores.
7. Start and hand tighten the remaining fuel rail bolts.

Caution: Refer to Fastener Caution in the Preface section.

8. Tighten the bank 1 and bank 2 fuel rail bolts.

•	Tighten the inner fuel rail bolts to 10 N·m (89 lb in).

•	Tighten the outer fuel rail bolts to 10 N·m (89 lb in).

9. Replace any wire harness tie straps cut from the fuel rails.
10. Install the cylinder head. Refer to Cylinder Head Replacement - Left Side or Cylinder Head Replacement - Right Side
11. Install the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement : LF1 or LFW .
12. Inspect for fuel leaks using the following procedure:

12.1.

Turn ON the ignition, with the engine OFF for 2 seconds.

12.2.

Turn OFF the ignition, for 10 seconds.

12.3.

Turn ON the ignition, with the engine OFF.

12.4.

Inspect for fuel leaks.

Note: Before installing the foam insulator, remove any remaining fuel from the injector well.

13. Install the foam insulator to the fuel rails.
14. Install the inlet manifold. Refer to Inlet Manifold Replacement .
15. Install the fuel pipe shield. Refer to Fuel Pipe Shield Replacement : LF1 or LFW .
16. Install the low side fuel pressure service port cap.