Ethanol is the killer of all things marine engine...not a political statement. Your fuel system is hating life in the subsidized corn market, especially the pre-2004 engines which were produced prior to ethanol being introduced to gasoline. If you have the option to get gasoline without ethanol, do it and do it always. For those of use who can't (especially if you live in Commiefornia), you will need to have your fuel injectors cleaned periodically because of the various issues ethanol creates in ALL gasoline fuel systems. We do not recommend using ONLY fuel injector cleaner or other off the shelf remedies, they just don't fix the problem of a leaking, stuck or poor spray pattern fuel injector. Instead, we remove, flow test, clean and re-install existing operational injectors and provide our customers with a before and after injector flow/spray pattern readout. Obviously, if you have a non-functioning injector, replace it but for 99% of the time we come across injector issues, this is the remedy.
This write up is a general for all GM based engines and does not include the Raptors produced from 2015 to present (although I'm going to do mine this fall and write it up then) and uses an outside vendor in Torrance, CA to service the injectors. They are rcfuelinjection.com and can be researched and contacted prior to servicing your fuel system.
Extreme caution is advised for this operation and it must be stated, NO SMOKING OR OPEN FLAMES WITHIN 100 FEET of someone performing this job. Keep a fire extinguisher handy and for the love of all things boat, don't try and take shortcuts. Also, don't do this job if you are not confident in your mechanical skills which is somehow different than not having mechanical skills but falls in the same category as DON'T BE A DUMBASS HANDLING FLAMMABLE LIQUIDS. Gasoline is a flammable liquid.
Incorrect installation or fuel components can lead to an extremely hazardous situation and cause fire, death and dismemberment and sadness in others. Do it right or have someone qualified do it for you.
1) DISCONNECT THE BATTERY OR BATTERIES to eliminate potential spark hazards during repairs.
2) Relieve the fuel rail pressure via the Schrader valve located on the fuel rail. These usually have a cap similar or exactly like a bicycle tire. They will spit fuel out when the center pin is pressed until the pressure is drained off. Have a collection device like an absorbent diaper from a marine store, a wad of paper towels or cloth towel to catch the fuel as the pressure is released. The amount will vary but is usually no more than 1oz.
3) After relieving the fuel pressure, remove each injector electrical connection. These vary by engine and usually require a YouTube video to show you exactly how to do it. The automotive engines use the same style injector connections so look for a video with a GM engine that has similar injectors.
4) Identify the injector rail hold-down fasteners and remove them. There are usually four, one in each corner and they hold the injector fuel rails to the intake manifold. Most of the 2004+ engines are 10mm and pre-2004 are 7/16" heads.
5) Carefully lift up on the fuel rails either engine from or engine rear at the same time. If there's corrosion and visible crud around the injectors, expect some injectors near the rail where you're lifting to stay in the intake manifold. If they do, BE PREPARED TO COLLECT THE FUEL STILL IN THE RAIL and keep it from dripping everywhere. The injectors will most likely stay in the rail and the whole rail should pull evenly on each side but be aware some may not. Leave the high pressure fuel line connected to the rails, it does not need to be removed
6) Use needle nose pliers and remove the metal retainer clips that hold the injectors to the fuel rail being careful to not let them go flying during removal. Take note of how the injector clips are indexed to the injector so during installation they are done properly. Keep the retainers together and off to the side.
7) After all the retainers are removed, have quart sized container ready to catch the remaining fuel left in the fuel rail when you remove the first fuel injector.
9) Hold the injector rails so the injectors are now vertical prepare to remove the bottom injector from one rail and catch the fuel as the injector is removed. Place the bucket under the injector being removed and wiggle it out of the rail. The injectors have o-rings at their interface with the rail and intake manifold so after their retainers are removed, they should come out with some motivation. Once the lowest injector is removed from the rail, the remains fuel in that side of the rail will drain out into the container.
10) Remove the lower injector from the other rail and drain that side of fuel as well.
11) After the fuel has been drained from the rails, each individual injector can now be removed in random order. Label the injectors with their appropriate cylinder number and set aside.
12) Check all injectors for upper and lower o-rings during removal. It is important for the shop to see what size o-rings were used because they provide new ones after cleaning. If some injectors do not have both, check the respective intake manifold and fuel rail injector positions for the missing o-rings and remove as required.
13) Wrap each labeled injector in a paper towel and then place all the injectors in a suitable shipping container. You will be shipping them to RC Fuel Injection if you do not have someone local who can provide this service. They can be contacted at RCfuelinjection.com website for full shipping details.
Installation is opposite of removal but BE SURE to grease the new o-rings prior to installation in the fuel rail AND the intake manifold. Bleed the air from the fuel rails by cycling the ignition several times and relieving the air through the Schrader valve on the fuel rail prior to starting the first time. Now enjoy your back-to-OEM specification fuel delivery and engine power!!!
This write up is a general for all GM based engines and does not include the Raptors produced from 2015 to present (although I'm going to do mine this fall and write it up then) and uses an outside vendor in Torrance, CA to service the injectors. They are rcfuelinjection.com and can be researched and contacted prior to servicing your fuel system.
Extreme caution is advised for this operation and it must be stated, NO SMOKING OR OPEN FLAMES WITHIN 100 FEET of someone performing this job. Keep a fire extinguisher handy and for the love of all things boat, don't try and take shortcuts. Also, don't do this job if you are not confident in your mechanical skills which is somehow different than not having mechanical skills but falls in the same category as DON'T BE A DUMBASS HANDLING FLAMMABLE LIQUIDS. Gasoline is a flammable liquid.
Incorrect installation or fuel components can lead to an extremely hazardous situation and cause fire, death and dismemberment and sadness in others. Do it right or have someone qualified do it for you.
1) DISCONNECT THE BATTERY OR BATTERIES to eliminate potential spark hazards during repairs.
2) Relieve the fuel rail pressure via the Schrader valve located on the fuel rail. These usually have a cap similar or exactly like a bicycle tire. They will spit fuel out when the center pin is pressed until the pressure is drained off. Have a collection device like an absorbent diaper from a marine store, a wad of paper towels or cloth towel to catch the fuel as the pressure is released. The amount will vary but is usually no more than 1oz.
3) After relieving the fuel pressure, remove each injector electrical connection. These vary by engine and usually require a YouTube video to show you exactly how to do it. The automotive engines use the same style injector connections so look for a video with a GM engine that has similar injectors.
4) Identify the injector rail hold-down fasteners and remove them. There are usually four, one in each corner and they hold the injector fuel rails to the intake manifold. Most of the 2004+ engines are 10mm and pre-2004 are 7/16" heads.
5) Carefully lift up on the fuel rails either engine from or engine rear at the same time. If there's corrosion and visible crud around the injectors, expect some injectors near the rail where you're lifting to stay in the intake manifold. If they do, BE PREPARED TO COLLECT THE FUEL STILL IN THE RAIL and keep it from dripping everywhere. The injectors will most likely stay in the rail and the whole rail should pull evenly on each side but be aware some may not. Leave the high pressure fuel line connected to the rails, it does not need to be removed
6) Use needle nose pliers and remove the metal retainer clips that hold the injectors to the fuel rail being careful to not let them go flying during removal. Take note of how the injector clips are indexed to the injector so during installation they are done properly. Keep the retainers together and off to the side.
7) After all the retainers are removed, have quart sized container ready to catch the remaining fuel left in the fuel rail when you remove the first fuel injector.
9) Hold the injector rails so the injectors are now vertical prepare to remove the bottom injector from one rail and catch the fuel as the injector is removed. Place the bucket under the injector being removed and wiggle it out of the rail. The injectors have o-rings at their interface with the rail and intake manifold so after their retainers are removed, they should come out with some motivation. Once the lowest injector is removed from the rail, the remains fuel in that side of the rail will drain out into the container.
10) Remove the lower injector from the other rail and drain that side of fuel as well.
11) After the fuel has been drained from the rails, each individual injector can now be removed in random order. Label the injectors with their appropriate cylinder number and set aside.
12) Check all injectors for upper and lower o-rings during removal. It is important for the shop to see what size o-rings were used because they provide new ones after cleaning. If some injectors do not have both, check the respective intake manifold and fuel rail injector positions for the missing o-rings and remove as required.
13) Wrap each labeled injector in a paper towel and then place all the injectors in a suitable shipping container. You will be shipping them to RC Fuel Injection if you do not have someone local who can provide this service. They can be contacted at RCfuelinjection.com website for full shipping details.
Installation is opposite of removal but BE SURE to grease the new o-rings prior to installation in the fuel rail AND the intake manifold. Bleed the air from the fuel rails by cycling the ignition several times and relieving the air through the Schrader valve on the fuel rail prior to starting the first time. Now enjoy your back-to-OEM specification fuel delivery and engine power!!!
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