Procedures

REMOVAL

Fuel Rail:

WARNING: NO SPARKS, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.

1. Disconnect negative battery cable.
2. Remove the engine cover.
3. Disconnect the intake manifold air inlet duct and position aside.
4. Disconnect the fuel rail pressure and control valve wiring harness connectors.
5. Remove engine harness retaining bolts and unclip the engine harness from the fuel rail.
6. Remove injector high pressure lines.
7. Remove fuel rail retaining bolts.

CAUTION: When slackening and tightening fuel injection line union nuts, counter hold with wrench at threaded connection. ON NO ACCOUNT exceed the tightening torque at any time. Do NOT crimp or bend lines.

NOTE: After removing lines, seal connections and ensure cleanliness.

8. Detach fuel return flow line to high pressure pump at rail.
9. Detach fuel return flow line at banjo bolt.
10. Remove fuel rail.

INSTALLATION

WARNING: NO FIRE, FLAMES OR SMOKING. RISK OF POISONING FROM INHALING OR SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.

1. Loosely position fuel rail into proper position on the cylinder head and hand tighten the fasteners
2. Connect the fuel pressure control valve harness connector.
3. Connect the fuel return lines at the banjo bolt.

CAUTION: Inspect sealing cones at the lines. Replace as necessary. Ensure that all fuel pressure lines are exactly located in original position.

4. Install the high pressure fuel lines and hand tighten

CAUTION: When tightening fuel injection line union nuts, counter hold with a wrench at the thread connection. ON NO ACCOUNT exceed the tightening torque at any time.

5. Tighten fuel rail bolts to 14 N.m (124 lbs in).
6. Reconnect engine harness electrical connectors
7. Connect the intake manifold air inlet duct
8. Connect negative battery cable

CAUTION: Care must be taken when installing the engine cover. Assure the proper routing of the fuel injector return fuel hose to the banjo bolt fitting in the left rear corner of the cover. Failure to do so may pinch or damage the hose causing fuel leakage or a driveability concern.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.

9. Start engine, run for a few minutes, turn the engine off and inspect for leaks (Refer to FUEL SYSTEM - WARNING).