Fuel Rail (G1817177): Removal

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

CAUTION: Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
This procedure contains illustrations showing certain components removed to provide extra clarity.

Always follow the Diesel fuel system health and safety precautions, when carrying out any repairs to the fuel system.
Refer to: DIESEL FUEL SYSTEM HEALTH AND SAFETY PRECAUTIONS
Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
Refer to: FUEL INJECTION COMPONENT CLEANING
Disconnect the startup battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
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Remove the engine cover.
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Remove the noise, vibration and harshness (NVH) material.
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Remove the oil gauge bracket bolt and reposition away from the inlet manifold.
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Release the fuel delivery pipes.
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Release the pipe from the retaining clip.
CAUTION:
- Remove and discard the gasket.
- Remove and discard the O-ring seal.
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Remove the Exhaust Gas Recirculation (EGR) pipe
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Release the fuel delivery pipes from the 2 retaining clips.
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Disconnect the 4 fuel injector electrical connectors.
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Remove and discard the high pressure fuel pipes.
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- Remove the fuel delivery line from the fuel rail.
- Disconnect the electrical connector from the fuel rail.
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Remove the high pressure pipe from the fuel rail.
NOTE: If equipped.

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Disconnect the EGR valve electrical connector.
NOTE: If equipped.

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Remove the EGR valve pipe.
NOTE: If equipped.

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Remove and discard the EGR valve pipe gasket.
NOTE: If equipped.

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Release the EGR valve assembly and reposition away from its original position.
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Remove the fuel pipe bracket.
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Release the fuel pipe from the fuel injection pump.
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Remove and discard the fuel supply pipe.
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disconnect the electrical connector from the fuel rail.
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Remove the fuel rail bracket.
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Release the 2 fuel rail bolts and remove the fuel rail.