Removal Procedure

WARNING: This page is about a different variant/trim than selected.

Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (Single Battery) , or Battery Negative Cable Disconnection and Connection (Dual Battery)
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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.

Remove the fuel pump insulator (1). Fuel Pump Insulator Replacement
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NOTE:
Do NOT reuse the fuel feed intermediate pipe. If the fuel feed intermediate pipe fittings are loosened or the pipe is removed, the pipe MUST be replaced.

Remove and DISCARD the fuel feed intermediate pipe - position 1. Fuel Feed Intermediate Pipe Replacement - Position 1
Remove the fuel feed pipe - at engine. Fuel Feed Pipe Replacement (Short/Long Wheel Base) , or Fuel Feed Pipe Replacement (Chassis Cab Front Tank) , or Fuel Feed Pipe Replacement (Chassis Cab Rear Tank) , or Fuel Feed Pipe Replacement (At Engine)
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Disconnect the electrical connector (1).
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Open the tape (1) holding the fuel injector wiring harness (2) to the fuel injection fuel rail.
Disconnect the fuel injector wiring harness (2) from the fuel injectors, the fuel injection fuel rail fuel pressure sensor, and the bracket.
Reposition the fuel injector wiring harness (2) to make room for the special tools.
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NOTE:
The fuel injection fuel rail bolts are retained with the fuel injection fuel rail insulators and may be difficult to remove.

Remove the fuel injection fuel rail bolts (1).
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NOTE:
The EN-49248 remover hooks MUST be properly seated on the underside of the fuel injection fuel rail.

Install the EN-49248 remover components (1) and slowly work the fuel injection fuel rail (2) upwards in small, even increments.
Once the fuel injection fuel rail (2) is free, remove the EN-49248 remover components (1).
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CAUTION:
- Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
- Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.
Remove the fuel injection fuel rail (1).
Remove the fuel injection fuel rail fuel pressure sensor. Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement
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Inspect the fuel injection fuel rail insulators (1) and replace if necessary.