Removal

REMOVAL

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.




1. Disconnect both negative battery cables at both batteries. Isolate ends of both cables.

2. Disconnect electrical connector at fuel pressure sensor.

3. Remove banjo bolt at fuel limiting valve.

4. Disconnect necessary wiring harness retention clips from intake manifold.

5. Lift 2 rubber covers to gain access to positive (+), intake heater cable nuts. Remove 2 nuts and remove 2 cables from studs.

6. Carefully remove 4 high-pressure fuel lines from top of fuel rail. Note position of each line while removing. Do not bend lines while removing.

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

7. Carefully remove 2 high-pressure fuel lines at each end of fuel rail. Note position of each line while removing. Do not bend lines while removing.

8. Remove fuel line connecting injection pump to fuel rail.

9. Remove three injection rail mounting bolts.

10. Remove rail from top of intake manifold.