Removal Procedure
WARNING: This page is about a different variant/trim than selected.
WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
WARNING:
Refer to Safety Goggles and Fuel Warning
WARNING:
Refer to Diesel/Gasoline Vapors Warning
CAUTION:
Refer to Fuel Contamination Caution
- Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (KL9)
- Remove Intake Manifold Cover. Refer to Intake Manifold Cover Replacement
- Remove Fuel Injection Fuel Feed Pipe Bracket Bolt (1)
- Loosen Fuel Injection Fuel Feed Pipe (2) @ Fuel Injection Pump (4)
- Loosen Fuel Injection Fuel Feed Pipe (2) @ Fuel Injection Fuel Rail (3)
- Remove and DISCARD Fuel Injection Fuel Feed Pipe (2)
- Close all open connections with suitable closure plugs.
- Remove and DISCARD Clamp (3)
- Disconnect Fuel Return Hose (4) @ Diesel Fuel Separator (2)
- Remove Fuel Injector Insulator (1)
- Loosen Fuel Injection Fuel Feed Pipes (1) @ Fuel Injection Fuel Rail (3) (Qty: 4)
- Loosen Fuel Injection Fuel Feed Pipes (1) @ Fuel Injector (2) (Qty: 4)
- Remove and DISCARD Fuel Injection Fuel Feed Pipes (1) (Qty: 4)
- Disconnect the electrical connector:
- Fuel Pressure Sensor (1)
- Fuel Pressure Regulator (4)
- Remove Fuel Injection Fuel Rail Noise Shield (2)
- Remove Diesel Fuel Separator Hose Clamp (5)
- Disconnect Diesel Fuel Separator Hose (3) @ Fuel Injection Fuel Rail
- Remove Fuel Injection Fuel Rail Bolts (1) (Qty: 2)
- Remove Fuel Injection Fuel Rail (2)
Fig 1: Fuel Injection Fuel Feed Pipe, Fuel Injection Pump, Fuel Injection Fuel Rail And Bracket Bolt
NOTE:
Counterhold at the fuel injection pump connector (4).
Fig 4: Fuel Injection Fuel Rail Noise Shield, Diesel Fuel Separator Hose, Clamp And Electrical Connectors