Fuel Rail: Removal
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 .
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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
Remove the fuel injection pump noise insulator.
- WARNING: Fuel may remain pressurized in some fuel lines after the Fuel System Pressure Release procedure. Wear safety gloves and a face shield when disconnecting pressure lines to avoid skin and eye contact. Failure to follow this instruction may result in serious personal injury.NOTE: Be prepared to collect escaping fluid.NOTE: Always wrap the fuel line connection with a towel before disconnecting it.
- Detach the wiring harness retainer from the fuel tube bracket.
- Remove the high pressure fuel tube bracket bolts.
- Loosen the high pressure fuel tube flare nuts, remove and discard the high pressure fuel tube.
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- Detach the fuel charge wiring harness retainers from the fuel rail.
- Remove the fuel rail insulator.
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- Disconnect the fuel injector electrical connectors.
- Disconnect the FRP 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: The isolator on the bottom of the fuel injector may fall off during removal. Look for any loose pieces and remove them. If this occurs replace the fuel injector.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. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.
Remove the bolts and the fuel rail.
- Remove any of the fuel injectors that remained in the fuel rail.
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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.
- Remove and discard the fuel injector clips.
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NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the new fuel injector support rings.
Remove and discard the fuel injector O-ring seals and the fuel injector support rings.
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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.