Fuel Rail - Installation

INSTALLATION





1. Clean any dirt/debris from top of intake manifold and bottom of fuel rail.
2. Install fuel rail (6). Tighten bolts (7) to 24 Nm (18 ft. lbs.).
3. Install two new sealing washers to fuel line banjo bolt connecting injection pump to fuel rail. Tighten to 24 Nm (18 ft. lbs.).

CAUTION: WHEN LOOSENING OR TIGHTENING HIGH-PRESSURE LINE FITTINGS (11) ATTACHED TO A SEPARATE FITTING (12), USE A BACK-UP WRENCH ON FITTING (12). DO NOT ALLOW FITTING (12) TO ROTATE. DAMAGE TO BOTH FUEL LINE AND FITTING WILL RESULT.

NOTE: Noise isolators (14) are used on the six high-pressure fuel lines. They should be positioned in the middle of the horizontal or longest straight section of each fuel line. The split on each isolator should be facing downward. Be sure the noise isolator is not touching another isolator or any other components.

4. If fuel tube at No. 6 cylinder has been replaced, tilt metal bracket (4) upward to install the No. 6 fuel tube.
5. Install all high-pressure tubes to rail and fuel injectors. Tighten fittings (9 and 11) to 40 Nm (30 ft. lbs.).
6. Position the metal bracket (4) at the rear of cylinder head back and tighten bolts (3) to 43 Nm (32 ft. lbs.).





7. Install the oil dipstick nut and tighten to 9 Nm (80 in. lbs).
8. Install the oil dipstick bolt and tighten to 24 Nm (18 ft. lbs).
9. Connect necessary wiring harness retention clips to the intake manifold.
10. Connect the fuel pressure sensor (2) harness connector.





11. Connect both fuel injector harness connectors.
12. Connect the crankcase pressure sensor connector (2).
13. Install the CCV oil drains hoses (3) to cylinder head cover.





14. Install the EGR crossover tube cover (2). Tighten bolts (1) to 10 Nm (89 in. lbs).
15. Install the oil dipstick tube.
16. Connect both negative battery cables.
17. Start engine and check for leaks.