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Home >> Chevrolet >> 2018 >> Volt Premier >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel System- - 1.5L (L3A) - Repair Instructions >> Repair Instructions >> Fuel Injection Fuel Rail Assembly Removal and Installation >> Installation Procedure

Installation Procedure

  1. Clean and inspect the fuel injectors and the fuel injector rail. Do not remove the fuel injector from the fuel rail. Refer to Fuel Injector and Fuel Injector Bore Cleaning and Inspection .
  2. GM3764347Courtesy of GENERAL MOTORS COMPANY

    Install a NEW combustion fuel injector seal (1) to the EN-51146-2-2  mounting sleeve-long (2).

  3. GM2918345Courtesy of GENERAL MOTORS COMPANY

    Use the EN-51146-2-6-1  slider outside (1) to push down the combustion fuel injector seal (2) on the EN-51146-2-2  mounting sleeve-long (3).

  4. GM3764346Courtesy of GENERAL MOTORS COMPANY

    Push the combustion fuel injector seal (2) over the EN-51146-2-2  mounting sleeve-long, use the EN-51146-2-6-1  slider outside (1) to the fuel injector (3).

  5. Remove the EN-51146-2-2  mounting sleeve-long with the EN-51146-2-1  stylus from the EN-51146-2-6-1  slider outside.
  6. Install a NEW combustion fuel injector seal to the EN-51146-2-3  mounting sleeve-short.
  7. Use the EN-51146-2-6-1  slider outside to push down the combustion fuel injector seal on the EN-51146-2-2  mounting sleeve-short.
  8. Push the combustion fuel injector seal over the EN-51146-2-3  mounting sleeve-short, use the EN-51146-2-6-1  slider outside to the fuel injector.
  9. Remove the EN-51146-2-3  mounting sleeve-short with the EN-51146-2-1  stylus from the EN-51146-2-6-1  slider outside.
  10. GM3621254Courtesy of GENERAL MOTORS COMPANY

    Before using the EN-51146-2-4  pre-sizing tool (1), check if the fuel injector limiter (2) is in the right position.

  11. GM2918347Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    First form the combustion fuel injector seals a bit with finger and thumb.

    Push the EN-51146-2-4  pre-sizing tool (1) over the fuel injector (2).

  12. GM2918354Courtesy of GENERAL MOTORS COMPANY

    Tighten the nut (2) and counterhold at the spanner flat of the EN-51146-2-4  pre-sizing tool thread (1) until the measure (a) of 4.5 mm (0.177 in) is reached.

  13. Loosen the nut (2) of the EN-51146-2-4  pre-sizing tool.
  14. GM2918355Courtesy of GENERAL MOTORS COMPANY

    Install the EN-51146-2-4-7  take off chassis (2) to the EN-51146-2-4  pre-sizing tool (3).

  15. Install the EN-51146-2-4-6  screw M10 (1) to the EN-51146-2-4-7  take off chassis (2), and tighten until the EN-51146-2-4  pre-sizing tool (3) is loosened.
  16. GM2968075Courtesy of GENERAL MOTORS COMPANY

    Install the EN-51146-2-5  calibration tool (2) rotary to the fuel injector (1), as shown in the graphic.

  17. Remove the EN-51146-2-5  calibration tool from the fuel injector.
  18. GM2918356Courtesy of GENERAL MOTORS COMPANY
    WARNING:

    The fuel injector seals must fit properly in the relative groove. Overlapping of the fuel injector seals with the external surface of the injector must be avoided. If the seals are installed incorrectly, it could cause leaks and risk of injury.

    Check the combustion fuel injector seals (2 seals each fuel injector) for correct seat:

    • The seal must not be too large, buckled or corrugated (1).
    • The seal must be fixed tight and accurate (2).
  19. If the seals are installed not correctly, repeat the steps 27 - 29 of the removal procedure and the steps 1 - 19 of the installation procedure.
  20. GM2918386Courtesy of GENERAL MOTORS COMPANY

    Install the 4 EN-51146-2-5  calibration tools (2) rotary to the fuel injectors (1).

  21. Remove the fuel injector assembly with the EN-51146-100  plate from the bench vise.
  22. GM2918404Courtesy of GENERAL MOTORS COMPANY

    Remove the 8 plate bolts (1) and remove EN-51146-100  plate (2), counterhold with a wrench (4) at the EN-51146-1-1  supports (3).

  23. GM2918395Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Never loosen both EN-51146-1-1  supports at the same time. Failure to follow this caution could cause leaks or malfunction after installation. It is only possible, when the fuel injector will be replaced.

    Remove one EN-51146-1-1  support (2) from the fuel injector (3).

    24. NOTE:

    DO NOT reuse the old fuel injector bolt.

  24. Apply thread lock agent to the NEW fuel injector bolt (1).
  25. Install NEW fuel injector bolt to the fuel injector and tighten to 5 N.m (44 lb in).
  26. GM2918396Courtesy of GENERAL MOTORS COMPANY

    Remove the EN-51146-1-1  support (1) from the fuel injector (3).

    27. NOTE:

    DO NOT reuse the old fuel injector bolt.

  27. Apply thread lock agent to the NEW fuel injector bolt (2).
  28. Install a NEW fuel injector bolt to the fuel injector and tighten to 5 N.m (44 lb in).
  29. Repeat the steps 22 - 27 for the other 3 injectors.
  30. Clean the fuel injector bores at the cylinder head. Refer to Fuel Injector and Fuel Injector Bore Cleaning and Inspection .
  31. GM3764254Courtesy of GENERAL MOTORS COMPANY

    Inspect the fuel injector rail assembly:

    • Check the 4 fuel injector for damage.
    • Check the 8 fuel injector seals for correct seat.
    • Check if all bolts (3) with decoupling elements (1) and retainer (2) are complete.
  32. Remove the 4 EN-51146-2-5  calibration tools from the fuel injector.
  33. GM3656897Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    During the installation of the fuel rail and injector assembly, ensure that the fuel injectors are positioned straight into the injector opening. Failure to follow this caution can tilt or bend the injectors and could cause leaks or malfunction after installation.

    Install carefully the fuel rail assembly (1).

  34. Push the fuel injectors slightly in their seats.
  35. Fig 1: Fuel Rail Bolt Tightening Sequence
    GM3656901Courtesy of GENERAL MOTORS COMPANY

    Tighten the 8 fuel rail bolts in the sequence as shown to 10 N.m (89 lb in).

  36. GM3682448Courtesy of GENERAL MOTORS COMPANY

    Fuel Injection Fuel Rail Wiring Harness (1) - Connect

  37. Fuel Feed Intermediate Pipe Replacement  - Install
  38. Ignition Coil Replacement  - Install [4x].
  39. After replacement of any components of the fuel injection systems, use a scan tool to reset functions. Refer to Control Module References .
    40. WARNING:

    Fuel escapes - observe safety measures and national legislation. Failure to comply could result in personal injury.

    NOTE:

    Ensure that all work at the engine is finished.

  40. Perform a fuel rail assembly leak test.
    1. Start the engine.
    2. Check the fuel system for leaks.
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