Fuel Rail: Removal

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

NOTE: Whenever the turbocharger air intake system components are removed, always cover the open ports to protect them from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All of the components should be inspected and cleaned, if needed, prior to installation or reassembly.

NOTE: Special attention needs to be given to the sealing ports for the oil feed, the oil drain, and the coolant lines, on turbocharged engines. The sealing ports must be totally clean and free from O-ring residue, have no damage to the sealing surface and the lines to ensure that there are no leaks or repeat repairs.

NOTE: During the removal or installation of components, cap, tape or otherwise appropriately protect all openings and tubes/fittings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

Release the fuel system pressure. Refer to: Fuel System Pressure Release .
Remove the intake manifold. Refer to: Intake Manifold .
1. Remove the air cleaner outlet pipe retainer.
2. Disconnect the quick release coupling and detach the hose retainers. Refer to: Quick Release Coupling .
- Loosen the clamps and remove the air cleaner outlet pipe.
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NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the high-pressure fuel pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of high-pressure fuel pump flare nut.

Remove the high-pressure fuel tube retaining nut and bolt. Loosen the high-pressure fuel tube flare nuts, disconnect, remove and discard the high-pressure fuel tube.

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Detach the coolant hose from the retainers. Disconnect the electrical connector retainer from the fuel rail tab. Remove the fuel rail insulator.

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Disconnect the fuel injector electrical connectors. Disconnect the fuel rail pressure sensor electrical connector.

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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 heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the fuel injector by hand to break it loose may allow the injector to be removed by hand.

Remove the fuel rail bolts, then remove 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 fuel 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: 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.

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

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

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NOTE: Note the correct orientation of the fuel injector support rings, to insure the correct installation of the new fuel injector support rings.
- Remove and discard the fuel injector O-rings.
- Remove and discard the fuel injector support rings.
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NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.
1. Pull the lower Teflon® seal away from the injector.
2. Carefully cut, remove and discard the lower fuel injector Teflon® seals.

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