Fuel Rail: Service and Repair

Fuel Injection Supply Manifold

Special Service Tools






Fuel spring lock decoupling tool

310-D005

Removal
1 Remove the cover and disconnect the battery ground cable. For additional information, refer to Specifications [1][2]Battery
2
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.
3
WARNING: Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
Using the special tool, disconnect the fuel line. For additional information, refer to Spring Lock Couplings Spring Lock Couplings
4 Remove the LH charge air cooler. For additional information, refer to Charge Air Cooler LH Charge Air Cooler LH
5 Remove the RH charge air cooler. For additional information, refer to Charge Air Cooler RH Charge Air Cooler RH




6 Disconnect the fuel temperature sensor electrical connector.




7 Release the fuel injector wiring harness.
- Release the 4 clips.




8 Disconnect the fuel injector electrical connectors.
- Release the 8 clips.




9 Remove the fuel injection supply manifold.
- Remove the 4 Torx screws.
- Remove and discard the fuel injector O-ring seals.





10
NOTE:
Do not disassemble further if the component is removed for access only.
Release and remove the fuel injectors.
- Remove the 8 clips.
- Discard the O-ring seals.





11 Remove the fuel pressure sensor.
- Remove the 2 bolts.
- Discard the O-ring seals.





12
CAUTION: To prevent damage to components, use an additional wrench when loosening or tightening unions.
Remove the fuel temperature sensor.

Installation
1 Install the fuel temperature sensor.
- Clean the component mating faces.
- Apply sealant to the sensor thread.
- Tighten the sensor to 7 Nm (5 lb.ft).
2 Install the fuel pressure sensor.
- Clean the component mating faces.
- Install new O-ring seals.
- Tighten the bolts to 6 Nm (4 lb.ft).
3 Install the fuel injectors.
- Clean the component mating faces.
- Install new O-ring seals.
- Secure with the clips.
4 Install the fuel injection supply manifold.
- Clean the component mating faces.
- Install new O-ring seals.
- Tighten the Torx screws to 10 Nm (7 lb.ft).
5 Attach the fuel injector wiring harness.
- Secure the clips.
- Connect the electrical connectors.
6 Connect the fuel temperature sensor electrical connector.
7 Install the RH charge air cooler. For additional information, refer to Charge Air Cooler RH Charge Air Cooler RH
8 Install the LH charge air cooler. For additional information, refer to Charge Air Cooler LH Charge Air Cooler LH
9 Connect the fuel line to the fuel rail. For additional information, refer to Spring Lock Couplings Spring Lock Couplings

10 Connect the battery ground cable and install the cover. For additional information, refer to Specifications [1][2]Battery