Fuel Rail: Removal

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
Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe
Disconnect the high-pressure fuel pump electrical connector.

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NOTE: When removing or installing the high-pressure fuel pump insulator, spreading the openings will reduce the risk of damage.

Remove the high-pressure fuel pump insulator.

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Disconnect the electrical connector, then detach the wiring harness retainers and move out of the way.

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Remove the nuts, then remove the bracket.

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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.

Remove the high-pressure fuel tube bracket bolts. Loosen the high-pressure fuel tube flare nuts, then disconnect, remove and discard the high-pressure fuel tube.

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1. Detach the wire harness retainers from the fuel rail.
2. Remove the fuel rail insulator.
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1. Disconnect the wire harness retainer from the fuel rail.
2. Disconnect the fuel rail sensor electrical connector.
3. Disconnect the fuel injector electrical connectors.
4. Remove the fuel rail wire harness.
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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: 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. Wiggling the fuel injector and twisting the fuel injector by hand to break it loose may allow the fuel injector to be removed.
1. Use compressed air to 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.
2. Remove and discard the 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 with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur. Wiggling the fuel injector and twisting by hand to break it loose may allow the fuel injector to be removed.

NOTE: Commercially available OTC 5028 8-1/2" long slide hammer may be substituted for 307-005 where there are clearance concerns.

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., 10-206 Remover, Fuel Injector.

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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.
1. Thoroughly clean any residual fuel or foreign material from the cylinder head, the engine block, the general surrounding area of the fuel rails and the fuel injectors.
2. Using the special tool, clean the cylinder head fuel injector bores. Use Special Service Tool: 310-205 Fuel Injector Brush.
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NOTE: Note the correct orientation of the fuel injector support rings for correct installation.

Remove and discard the fuel injector O-rings. Remove and discard the fuel injector support rings.

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NOTE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

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

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