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High pressure fuel lines for fuel injector replacement

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16K views 24 replies 7 participants last post by  Joslynmaliky  
#1 ·
Okay going to try and keep this short.
I am in the process of replacing all 6 injectors on my LLT and I have to remove one of the high pressure lines to remove the fuel rail. The one I need to remove is u shaped one not sure if that matters.

It is recommended that I replace that hpf line and I just replaced that when I replaced my HPFP.

Why does it recommend I replace that line?
Can I go without replacing it?
Thanks.
 
#2 ·
It has to handle 3,000+ PSI. It has a tag on it that says replace if you remove. Mainly because it is a use once and throw away. You may get away with reusing it if you just did. The worst that happens is fuel will leak onto your engine and maybe catch on fire.
 
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#4 ·
Worth a read, and this was replacing the lines. I totally get trying to save when you can.
 
#5 ·
Thank you Long that was a good read. I am going to replace both HPF lines. Now if only I could get these fuel rails out. They keep getting stuck. It says to remove bank 2 first (driver side) but the rail keeps getting caught on the fuel pressure sensor for bank 1. I guess I have to try and pry the injectors out to get the rails out but with how tight it is I can't see a thing. I am afraid I going to break something. They always make it look and sound so easy. :confused::unsure::rolleyes:
 
#7 ·
So we have all the bolts out but neither rail wants to come out. They are hitting and catching on each other and the engine. My Haynes manual does not refer to any special tool except for when putting new o-rings on the injectors. Some videos have said to make sure we remove the injectors from the rail prior to realesing but that seems to be easier said then done.
 
#9 ·
I did remove the pressure sensor but there is still the place that sticks out where the pressure sensor screws into. There is just not clearance bank 2 catches on the place where the pressure sensor bolts in and bank one gets hung up on the engine. I have tried for hours now.

I am trying to get the injectors out of the rail so I can remove the rails and then remove the injectors and harness from the engine but I am afraid I am going to brake something.

Anyone have any advice please?
 
#13 ·
High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.


  1. Relieve the fuel system pressure.Fuel Pressure Relief
  2. Remove the fuel pipe shield. Fuel Pipe Shield Replacement
  3. Remove the intake manifold. Intake Manifold Replacement
  4. Remove the fuel injection fuel rail noise shield.
  5. Disconnect the engine wiring harness connectors from the fuel injector wiring harnesses as necessary.
  6. Unclip the fuel injector wiring harness connectors from the fuel feed pipe bracket as necessary.
  7. Remove and DISCARD any fuel injector wiring harness tie straps as necessary.
  8. Disconnect the fuel pressure sensor electrical connector.
  9. Remove the fuel pressure sensor. Fuel Pressure Sensor Replacement - Fuel Injection Fuel Rail (LF1) | Fuel Pressure Sensor Replacement - Fuel Injection Fuel Rail (LLT)
  10. Remove and DISCARD the fuel injection fuel rail crossover tube. Fuel Injection Fuel Rail Crossover Tube Replacement (LLT)

  11. Remove the fuel injection fuel rail bolts (2) from BOTH fuel injection fuel rails.
  12. Remove and DISCARD the fuel injector hold down clamps.

  13. NOTE
    Note
    Lift the rear of the fuel injection fuel rail first to ease removal.

    Carefully remove the bank 1 fuel injection fuel rail (1) from the engine.

  14. NOTE
    Note
    Whenever ANY fuel injector is removed from the cylinder head or the fuel injection fuel rail, the fuel injector MUST be rebuilt.

    Once the fuel injection fuel rail is removed, clean and inspect the fuel injectors. Fuel Rail and Injectors Cleaning and Inspection (LF1, LFW or LFX) | Fuel Rail and Injectors Cleaning and Inspection (LLT)
 
#16 ·
High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.



  1. Relieve the fuel system pressure.Fuel Pressure Relief
  2. Remove the fuel pipe shield. Fuel Pipe Shield Replacement
  3. Remove the intake manifold. Intake Manifold Replacement
  4. Remove the fuel injection fuel rail noise shield.
  5. Disconnect the engine wiring harness connectors from the fuel injector wiring harnesses as necessary.
  6. Unclip the fuel injector wiring harness connectors from the fuel feed pipe bracket as necessary.
  7. Remove and DISCARD any fuel injector wiring harness tie straps as necessary.
  8. Disconnect the fuel pressure sensor electrical connector.
  9. Remove the fuel pressure sensor. Fuel Pressure Sensor Replacement - Fuel Injection Fuel Rail (LF1) | Fuel Pressure Sensor Replacement - Fuel Injection Fuel Rail (LLT)
  10. Remove and DISCARD the fuel injection fuel rail crossover tube. Fuel Injection Fuel Rail Crossover Tube Replacement (LLT)


  11. Remove the fuel injection fuel rail bolts (2) from BOTH fuel injection fuel rails.
  12. Remove and DISCARD the fuel injector hold down clamps.

  13. NOTE
    Note
    Lift the rear of the fuel injection fuel rail first to ease removal.


    Carefully remove the bank 1 fuel injection fuel rail (1) from the engine.

  14. NOTE
    Note
    Whenever ANY fuel injector is removed from the cylinder head or the fuel injection fuel rail, the fuel injector MUST be rebuilt.


    Once the fuel injection fuel rail is removed, clean and inspect the fuel injectors. Fuel Rail and Injectors Cleaning and Inspection (LF1, LFW or LFX) | Fuel Rail and Injectors Cleaning and Inspection (LLT)

I am stuck on step 12. What clamps? I bought new injectors that are already equipped with the needed o-rings.

Oh and my mechanic says to use di-electric (not sure of spelling but am sure you get the gist) greese on the seals, any thoughts on that?
 
#14 ·
Fuel Rail and Injectors Cleaning and Inspection (LLT)
Fuel Rail and Injectors Cleaning and Inspection (LLT)
  • Special Tools
  • EN-47909 Injector Bore and Sleeve Cleaning Kit
  • EN-48266 Injector Seal Installer and Sizer
For equivalent regional tools, refer to Special Tools.


  1. Remove the injectors from the fuel rail.

  2. Remove the wiring harness from the fuel injectors.

  3. Remove and discard the fuel injector hold-down clamp.

  4. Remove and discard the fuel injector O-ring and plastic spacer.

  5. Remove and discard the isolator cup and retainer.

  6. Remove and discard the fuel injector seal.


  7. NOTE
    Note
    Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.

    Remove and discard the fuel pressure sensor.

  8. NOTE
    Note
    Do not soak or submerge the fuel rail or injectors in solvent.

    Clean the exterior of the fuel rail and injectors with solvent.

  9. 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 feed fitting
    • Damage to the threads in the fuel pressure sensor bore

  10. NOTE
    Note
    Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.

    Install the fuel pressure sensor.

    • NOTE
      Note
      Ensure that the fuel rail threads have been cleaned of any excess fuel, or the NEW fuel injection fuel rail fuel pressure sensor will NOT seal properly.

      Lubricate the threads and the sealing cone in the fuel rail with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended lubricant.
    • Lubricate the threads and the sealing cone on the NEW fuel injection fuel rail fuel pressure sensor with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended lubricant.
    • Install the NEW fuel injection fuel rail fuel pressure sensor hand tight.
    • Remove the NEW fuel injection fuel rail fuel pressure sensor, re-lubricate following steps 1 and 2 above.

    • CAUTION
      Caution
      Refer to Fastener Caution.

      Install the NEW fuel injection fuel rail fuel pressure sensor and tighten to 33 N·m (25 lb ft).

  11. Inspect the fuel injectors for the following conditions:
    • Damage to the fuel injector connector (1)
    • Damage to the injector locator tab (2)
    • Damage to the fuel inlet cone (3)
    • Damage the plastic fuel injector body (4)
    • Damage to the isolator cup retainer groove (5)
    • Damage to the teflon seal (6)
    • Damage to the fuel injector tip (7)
  12. Replace the fuel rail or injector if any damage is found. Do not attempt to repair a fuel rail or injector.

  13. Lubricate the NEW O-ring with one drop of clean engine oil.

  14. NOTE
    Note
    The plastic spacer has a top and a bottom. The top, O-ring sealing area, is wider.

    Install the NEW plastic spacer and O-ring on the injector.

  15. Install the isolator cup and retainer.


  16. NOTE
    Note
    Do not use any type of lubricant when installing the NEW seal.

    Install a NEW seal on the injector using the EN-48266-1. The seal must be installed/slid into the recessed area of the fuel injector.

  17. Compress the seal with your fingers before resizing the seal using the EN-48266-2.

  18. Install a NEW fuel injector hold-down clamp.

  19. Image



    CAUTION
    Caution
    Ensure the fuel injectors are installed in the correct orientation. Improper orientation of the fuel injectors may result in engine misfire and possible engine damage.

    The right side (bank 1) fuel injector wiring harness connectors (1) should point to the rear of the engine. The left side (bank 2) fuel injector wiring harness connectors (2) should point to the front of the engine.
 
#18 ·
When I pulled my rails out I had to shift one forward and the other back to pull them out.

On my LFX the clips were a pain to get off and when putting them back on it was a bear but not worth the price of picking up a $300 tool for one time usage. And all the tool does is hold the clips so they won't spread. I believe I used a pair of vice grips and a flat screwdriver to get the clips off and back on. The clips were a little bent but worked fine. It did make the tick of the injectors move around a little louder.
 
#21 ·
I can not no..

I sent my injectors in to someone to be flow tested, cleaned and rebuilt. I had 1 bad injector but the rest were fine. I removed the fuel rails and pulled the clips off the injectors then sent the injectors in and a week later had them back. Put back on the fuel rails with the clips to hold them in place and put the fuel rails back in, new high pressure fuel crossover, new pressure sensor , fired it up and it was fine. Since I didn't have the tool to put the clips back on my clips were slightly bent. Just makes the injector sound a little louder is all. I was told the tool takes a special touch to make it work right.
 
#24 ·
Since no one followed up on this and for posterity's sake, I want to add the following information. I used the information in this thread to decide to tackle my own injector replacement. Once I had reached the point at which Joslynmaliky (OP) had become hung up, and not being able to see TheFlash's post, and looking at my new injectors, I ascertained that the O-rings were what were binding the fuel rail from coming out. I carefully pried up on the rail, but it only pulled the injectors from their seat in the engine. At this point the injectors themselves were preventing the fuel rail from coming out. So I needed a way to separate the rail and injector. The first thing I tried worked, and did not damage the injectors or the rail. I didn't take a picture in the process, but I re-created what I did in the following picture, albeit with the rail and injector lying on the front shroud. I used a pair of long needle-nose pliers to open up the space between the rail and the spring clip, releasing the injector from the rail. This was the only part that was hard, everything else was as one would expect. Hope this helps.
598951
 
#25 ·
I was able to get my rails out as well but I had to slowly push each injector out of the rail with a flat head screw driver placed near where the injector meets the head. It was a very big process. You are correct though the fuel injectors had to be taken off the rail. They also had to go back in the same way. All of my codes are now gone and the car rides like a dream.