Direct Injection 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 CAC intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
Remove the intake manifold. Refer to: Intake Manifold .
Position the tubes aside, then remove the bolts and the rear high-pressure fuel pump shield.

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Remove the bolts and the bottom high pressure pump shield.

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Disconnect the high-pressure pump electrical connector.

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

Remove the high-pressure fuel pump cover.

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Detach the retainers, then remove the bolt and the bracket.

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NOTE: Always wrap the fuel line connection with a towel before disconnecting it.

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

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Remove the accessory drive belt from the generator and position aside. Refer to: Accessory Drive Belt .

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- Loosen the generator lower bolt and detach the retainer.
- Remove the upper bolt and position the grenerator aside.
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Remove the bolts and the upper generator bracket.

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Disconnect the fuel rail wire harness and the knock sensor electrical connectors.

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

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Detach the retainers and disconnect the electrical connectors.

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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., 310-206 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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