Fuel Rail: Removal

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

Release the fuel system pressure. Refer to: FUEL SYSTEM PRESSURE RELEASE .
Disconnect the battery. Refer to: Battery Disconnect and Connect - Vehicles With: Single Battery . Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries .
Remove the intake manifold. Refer to: Intake Manifold .
Drain the cooling system. Refer to: ENGINE COOLING SYSTEM DRAINING, VACUUM FILLING AND BLEEDING .
Remove the bolts and position the coolant crossover assembly aside.

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Remove the coolant crossover assembly gaskets and discard.

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Remove the coolant inlet pipe.

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Remove the coolant inlet pipe O-ring seals and discard.

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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 bracket nut, the high pressure fuel tube bracket bolt and discard. Disconnect the high pressure fuel tube flare nuts, remove the high pressure fuel tube and discard.

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Release the fuel injector wire harness retainers from the fuel rail.

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Disconnect the fuel injector wire harness connectors and the fuel rail pressure sensor wire connector.

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Detach the fuel injector wire harness electrical connector retainers and the fuel injector wire harness retainer from the fuel rail.

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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: When removing the fuel rails remove the left side fuel rail first.

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 injector by hand to break it loose may allow the injector to be removed by hand.

NOTE: Should any of the fuel injectors remain in the head, then the fuel injector electrical connectors will need to be disconnected as the fuel rail is being removed.

Remove the fuel rail bolts and remove the fuel rails. Discard the fuel rail bolts.

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Disconnect the fuel injector electrical connectors.

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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.

NOTE: Commercially available OTC 5028 8-1/2" long slide hammer may be substituted for 307-005 where there are clearance concerns.

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. Use the General Equipment: Slide Hammer

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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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