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. Remove the oil dipstick tube.
3. Remove bolts (1), and EGR crossover tube cover (2).





4. Remove the CCV oil drains hoses (3) from cylinder head cover.
5. Disconnect the crankcase pressure sensor connector (2).
6. Disconnect both fuel injector harness connectors.





7. Disconnect the fuel pressure sensor harness connector (2).
8. Disconnect necessary wiring harness retention clips from intake manifold.
9. Remove bolt and nut securing the oil dipstick tube.






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.

10. Remove the fuel tubes (8).
11. Loosen fittings (9) for all fuel tubes at fuel rail.

NOTE: Clean any dirt/debris from around fuel injector area.

12. If removing fuel tube at No. 6 cylinder, a bracket (4) is located above fuel tube connection at cylinder head. Two bolts (3) secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen (but do not remove) these two bracket bolts. Tilt bracket down to gain access to No. 6 fuel line connection.
13. Loosen fittings (11) and remove all fuel tubes (1). Note and mark position of each fuel tube while removing.
14. Remove the fuel return line banjo bolt at fuel rail and discard sealing washers.
15. Remove bolts (7) and the fuel rail (6).