Fuel Rail - 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.
2. Disconnect the fuel pressure sensor harness connector (2).
3. Disconnect necessary wiring harness retention clips from intake manifold.
4. Remove bolt and nut securing the oil dipstick tube.
5. Remove nut and the air intake heater cable.





6. Remove fuel line (8).
7. Loosen fittings (9).

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.

8. Loosen fittings (11) and remove all fuel lines (1). Note and mark position of each fuel line while removing.
9. Remove the fuel line banjo bolts connecting injection pump to fuel rail.
10. Remove bolts (7) and the fuel rail (6).