Fuel Rail: Removal
WARNING:
Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING:
Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.
NOTE:
A clean working environment is essential to prevent dirt or foreign material contamination.
- 2.NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
Remove the fuel injection pump noise insulator.
- 3.
Release the fuel system pressure, refer to Fuel System General Information .
- 4.
Disconnect the battery ground cable, refer to Battery, Mounting and Cables .
- 5.
Remove the intake manifold, refer to Engine 3.5L GTDI .
- 6.
Drain the cooling system, refer to Engine Cooling .
NOTE:
To release the fuel pressure in the high pressure fuel tube, wrap the high-pressure fuel pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of high-pressure fuel pump flare nut.
- 11.
Remove and discard the high pressure fuel tube bracket nut and the high pressure fuel tube bracket bolt. Disconnect the high pressure fuel tube flare nuts, remove and discard the high pressure fuel tube.
- 13.
Disconnect the fuel injector wire harness connectors and the fuel rail pressure sensor wire connector.
- 14.
Detach the fuel injector wire harness electrical connector retainers and the fuel injector wire harness retainer from the fuel rail.
- 15.NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.NOTE: Should any of the fuel injectors remain in the cylinder heads, then the fuel injector electrical connectors will need to be disconnected as the fuel rail is being removed.
Remove and discard the fuel rail bolts. Remove the fuel rails.
- 19.NOTE: Use minimal force to remove the fuel injectors that remained in the cylinder head with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur.
Using the Fuel Injector Remover tool, remove any of the fuel injectors that remained in the cylinder head. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand. Special Tool(s): Slide Hammer 307-005 (T59L-100-B) or equivalent and Remover, Fuel Injector 310-206..
- 20.NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.NOTE: Do not use compressed air to clean the tip of the fuel injector.NOTE: Do not use a brush to clean the tip of the fuel injector.
Using the Fuel Injector Brush, clean the fuel injector bore in the cylinder head. Special Tool(s): Brush, Fuel Injector 310-205.