Fuel Rail: Removal

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

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

Release the fuel system pressure. Refer to: Fuel System Pressure Release .
Disconnect the battery. Refer to: Battery Disconnect and Connect .
Remove the intake manifold. Refer to: Intake Manifold .
Remove the air cleaner outlet pipe.
1. Loosen the clamps.
2. Remove the bolt and the air cleaner outlet pipe.
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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
1. Disconnect the fuel injection pump electrical connector.
2. Remove the fuel injection pump noise insulator.
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Disconnect the EVAP canister purge valve electrical connector, detach the EVAP canister purge valve from the EVAP canister purge valve bracket and position it out of the way.

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NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of fuel injection pump flare nut.
1. Remove the high-pressure fuel tube bracket bolts.
2. Loosen the flare nuts.
3. Remove and discard the high-pressure fuel tube.
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1. Detach the retainers.
2. Remove the fuel rail insulator.
3. Disconnect the fuel injector electrical connectors.
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NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.

NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder head and require the use of a Fuel Injector Remover tool to extract.

Remove the bolts and the fuel rail.

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Remove the fuel injectors from the fuel rail.

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Remove and discard the fuel injector clips.

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NOTE: Use minimal force to remove the fuel injectors that remained in the cylinder head with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

Using the special tools, remove any of the fuel injectors that remained in the cylinder head. Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer., 310-206 Remover, Fuel Injector.

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NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

NOTE: Do not use compressed air to clean the tip of the fuel injector.

NOTE: Do not use a brush to clean the tip of the fuel injector.

Using the special tool, clean the cylinder head fuel injector bores. Use Special Service Tool: 310-205 Fuel Injector Brush.

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