Fuel Injection Fuel Rail Assembly Replacement - Bank 2

Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LLT)

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027)Fuel Pressure Relief (CH-48027) Fuel Pressure Relief (CH-48027)Fuel Pressure Relief (High Side) Fuel Pressure Relief (High Side).

2. Remove the fuel pipe shield. Refer to Fuel Pipe Shield Replacement Fuel Pipe Shield Replacement.




3. Remove the high pressure fuel sensor. Refer to Fuel Pressure Sensor Replacement - Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement - Fuel Injection Fuel Rail.

4. Remove the high pressure fuel pipe. Discard the pipe. Refer to Fuel Feed Intermediate Pipe Replacement (LLT) Fuel Feed Intermediate Pipe Replacement.

5. Remove the crossover tube. Refer to Fuel Injection Fuel Rail Crossover Tube Replacement (LLT) Fuel Injection Fuel Rail Crossover Tube Replacement. Discard this pipe.




6. Remove the fuel rail bolts (1) from both rails for clearances purposes.

7. Carefully remove the Bank 2 fuel rail (2) from the engine. Lift the rear of the rail to ease removal.

8. Remove and discard the direct fuel injector hold down clamps.

Note: The direct fuel injectors must be rebuilt whenever the injector has been released from the fuel rail or cylinder head.

9. Once the fuel rail is removed, remove the fuel injectors and rebuild them. Refer to Fuel Rail and Injectors Cleaning and Inspection (LLT) 62. Fuel Rail and Injectors Cleaning and Inspection.

Installation Procedure




1. Install the rebuilt direct fuel injectors (1) to the cylinder heads. Refer to Fuel Rail and Injectors Cleaning and Inspection (LLT) 62. Fuel Rail and Injectors Cleaning and Inspection.

2. Install new direct injector hold down clamps to the injectors.




3. On the new fuel rail, lubricate the fuel injector cups with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers [1][2]Computers and Control Systems

4. Carefully place the fuel rail (2) into position, placing the front into the fuel rail over the front injector and rotating the rear downward.

5. Install the 2 outer fuel rail bolts first, then the 2 inner bolts and hand tighten.





Caution: Refer to Fastener Caution Fastener Caution.

6. Tighten the fuel rail bolts in the sequence shown:

1. Tighten the Bank 1 fuel rail bolts first pass to 12 Nm (106 lb in).

2. Tighten the Bank 1 fuel rail bolts a final pass to 23 Nm (17 lb ft).

7. Install a NEW fuel rail crossover tube. Refer to Fuel Injection Fuel Rail Crossover Tube Replacement (LLT) Fuel Injection Fuel Rail Crossover Tube Replacement.

8. Install a NEW high pressure fuel pipe. Refer to Fuel Feed Intermediate Pipe Replacement (LLT) Fuel Feed Intermediate Pipe Replacement.




9. Install the high pressure fuel sensor. Refer to Fuel Pressure Sensor Replacement - Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement - Fuel Injection Fuel Rail.

10. Connect the fuel injector wiring harness electrical connector (1) from the fuel injectors, fuel rail and fuel pressure sensor.

11. Inspect for fuel leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.

2. Turn OFF the ignition, for 10 seconds.

3. Turn ON the ignition, with the engine OFF.

4. Inspect for fuel leaks.

12. Install the fuel pipe shield. Refer to Fuel Pipe Shield Replacement Fuel Pipe Shield Replacement.

13. Install the low side fuel pressure service port cap.

14. Install the fuel tank cap.