Fuel Rail: Removal

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.

WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

Release the fuel system pressure. Refer to: Fuel System Pressure Release .
Disconnect the battery. Refer to: Battery Disconnect and Connect .
Remove the ignition coil-on-plugs. Refer to: Ignition Coil-On-Plug .
Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
- Disconnect the crankcase ventilation tube quick release coupling. Release the hose retainer, release the clamp and then remove the crankcase ventilation tube. Refer to: Quick Release Coupling .
- Remove the TC air inlet pipe retaining nut, the ball stud and loosen the TC air inlet pipe clamp, then remove the TC inlet pipe.
  Torque: 44 lb.in (5 Nm)
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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.

Remove the high-pressure fuel pump noise insulator.

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- Release the wiring harness retainers. Disconnect the FRP sensor electrical connector, the fuel injection pump electrical connector and the CMP electrical connector. Position the wiring harness aside.
- Remove the ignition coil-on-plug mounting bracket retaining nut. Loosen the captured remaining ignition coil-on-plug mounting bracket retainers and then remove the ignition coil-on-plug mounting bracket.
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Remove the ignition coil-on-plug mounting bracket insulator.

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

Disconnect the high-pressure fuel tube flare nuts. Remove and discard the high-pressure fuel tube.

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Disconnect the fuel injector electrical connectors.

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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: Use compressed air and remove any dirt or foreign material from the cylinder head, the engine block and the general surrounding area of the fuel rail and the fuel injectors.

NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder head and require the use of a Fuel Injector Remover tool to extract.

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

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Remove the fuel injectors from the fuel rail.

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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.
1. 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, the engine block and the general surrounding area of the fuel rails and the fuel 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 engine cylinder head fuel injector bores. Use Special Service Tool: 310-205 Fuel Injector Brush.

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