Fuel Delivery - 2.2L Diesel: Rail-Fuel: Removal

WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1600 bar (23,200 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.

WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Risk of injury to eyes and skin from contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing.

Fig 1: Battery Location

Courtesy of DAIMLERCHRYSLER CORP.

1 - BATTERY

2 - PASSENGER SEAT

Disconnect negative battery (1) cable located under passenger seat.

Fig 2: Engine Cover Mounts

Courtesy of DAIMLERCHRYSLER CORP.

1 - ENGINE COVER RETAINING NUTS

2 - ENGINE COVER

3 - ENGINE COVER MOUNTS

4 - ENGINE COVER MOUNTING STUDS

Remove engine cover retaining nuts (1).
Remove engine cover (2).
Disconnect fuel rail pressure sensor and fuel pressure solenoid electrical connectors.
CAUTION: When loosening and tightening fuel injection line union nuts, counter hold with wrench at threaded connection. DO NOT exceed the tightening torque at any time. DO NOT crimp or bend lines.

NOTE: After removing lines, seal connections and ensure cleanliness.

Fig 3: FUEL RAIL MOUNTING BOLTS
Courtesy of DAIMLERCHRYSLER CORP.

1 - FUEL RAIL

2 - FUEL RAIL MOUNTING BOLTS
Remove injector high pressure lines (Refer to FUEL SYSTEM/FUEL DELIVERY/FUEL LINES - REMOVAL) . See Figure.
Remove pressure line of high pressure pump from rail. See Figure.
Detach fuel return flow line to high pressure pump at rail. See Figure.
Detach fuel return flow line to fuel filter at fuel rail. See Figure.
Remove fuel rail mounting bolts and remove fuel rail from cylinder head. See Fig 3.