Fuel Rail: Removal

Both fuel rails

Release the fuel system pressure. Refer to: Fuel System Pressure Release
Disconnect the battery. Refer to: Battery Disconnect and Connect
Remove the intake manifold. Refer to: Intake Manifold
NOTE: To release the fuel pressure in the fuel rail to fuel rail high-pressure fuel tube, wrap the fuel rail to fuel rail high-pressure fuel tube flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the fuel rail to fuel rail high-pressure fuel tube flare nuts.

Disconnect the fuel rail to fuel rail high-pressure fuel tube flare nuts, then remove and discard the fuel rail to fuel rail high-pressure fuel tube.

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Left fuel rail
Detach the wiring harness retainer.

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NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

NOTE: The isolator on the bottom of the fuel injector may fall off during removal. Look for any loose pieces and remove them. If this occurs replace the fuel injector.

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 head, then the fuel injector electrical connectors will need to be disconnected as the fuel rail is being removed.

Remove the fuel rail bolts, then remove the fuel rail.

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Disconnect the fuel injector electrical connectors.

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NOTE: The inlet stopper, the fuel injector O-ring seals and the fuel injector support rings may remain in the fuel rail, be sure to check and remove them along with any debris found in the fuel rail.

Remove the fuel injectors from the fuel rail.

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Right fuel rail
NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the high-pressure fuel tube flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of high-pressure fuel tube flare nuts.

Disconnect the high-pressure fuel pump-to-fuel rail high-pressure fuel tube flare nuts, then remove and discard the high-pressure fuel pump-to-fuel rail high-pressure fuel tube.

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Detach the wiring harness retainer.

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NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

NOTE: The isolator on the bottom of the fuel injector may fall off during removal. Look for any loose pieces and remove them. If this occurs replace the fuel injector.

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 head, then the fuel injector electrical connectors will need to be disconnected as the fuel rail is being removed.

Remove the fuel rail bolts, then remove the fuel rail.

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Disconnect the fuel injector electrical connectors.

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NOTE: The inlet stopper, the fuel injector O-ring seals and the fuel injector support rings may remain in the fuel rail, be sure to check and remove them along with any debris found in the fuel rail.

Remove the fuel injectors from the fuel rail.

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Both fuel rails
Remove and discard the fuel injector clips.

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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. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

Using the special tools, remove any of the fuel injectors that remained in the cylinder head. Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer., 310-206 Remover, Fuel Injector.

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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 special tool, clean the cylinder head fuel injector bores. Use Special Service Tool: 310-205 Fuel Injector Brush.

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1. Remove and discard the fuel injector O-ring seals.
2. NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the new fuel injector support rings.
  
  Remove and discard the fuel injector support rings.
3. Inspect the inlet stopper, if it is damaged or comes off then discard the inlet stopper. The inlet stopper is not needed for proper function. Ensure that any debris from the inlet stopper are removed. If the inlet stopper is intact and undamaged do not remove the inlet stopper from the fuel injector.
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NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injector.

NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.
1. Pull the lower Teflon® seal away from the injector.
2. Carefully cut and discard the lower fuel injector Teflon® seal.

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