Fuel Rail Assembly Replacement - Bank 1

FUEL RAIL ASSEMBLY REPLACEMENT - BANK 1

REMOVAL PROCEDURE




1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Reposition the inlet hose clamps.
4. Remove the inlet hose from the radiator.
5. Remove the inlet hose from the water outlet tube.




6. Remove the bolt attaching the positive battery cable junction box and bracket and move it out of the way.
7. Loosen the charged air cooler inlet duct to turbocharger clamp (1).

IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose-The hose can be torn or damaged-Loosen the hose by twisting.

8. Remove the charged air cooler inlet duct from the turbocharger.




9. Disconnect the glow plug relay electrical connectors (1, 2, 3).
10. Remove the glow plug bracket.




11. Disconnect the engine wiring harness connectors. Lift up on the latch in order to disconnect the connectors.
12. Remove the engine connector bracket and set aside.
13. Disconnect the fuel in-line and return lines.
14. Remove the L-bracket holding the fuel lines.




15. Reposition the positive crankcase ventilation (PCV) hose clamp.
16. Remove the PCV hose and move it out of the way.
17. Remove the water pipe outlet from the thermostat housing.
18. Remove the drive belt.




19. Remove the air conditioning (A/C) compressor bolts and position aside.




20. Remove the line from the junction block to the injection pump.




21. Loosen the fuel return rear pipe (1) at the back end of the fuel rail and remove.




22. Remove the fuel junction block.




23. Remove the fuel injector feed pipe retainer bolts and retainers.
24. Remove the fuel injector pipes.




25. Remove the fuel rail bolts and rail.

INSTALLATION PROCEDURE

NOTE: Refer to Fastener Notice in Service Precautions.




1. Install the fuel rail and bolts.

Tighten
Tighten the bolts to 26 N.m (19 lb ft).




2. Install the fuel injector feed pipes.

Tighten
Tighten the fittings to 41 N.m (30 lb ft).

3. Install the fuel injector feed pipe retainers and bolts.

Tighten
Tighten the bolts to 4 N.m (35 lb in).




4. Install the fuel junction block.

Tighten
Tighten the fittings to 25 N.m (18 lb ft).




5. Connect the fuel return rear pipe (1) to the back end of the fuel rail.

Tighten
Tighten the fitting to 44 N.m (32 lb ft).




6. Install the line from the junction block to the injection pump.

Tighten
Tighten the fitting to 40 N.m (30 lb ft).




7. Install the A/C compressor bolts.

Tighten
Tighten the bolts to 50 N.m (37 lb ft).

8. Install drive belt.
9. Install the water outlet pipe to thermostat housing.




10. Install the PCV hose.
11. Reposition the PCV hose clamp.
12. Install the L-bracket holding the fuel lines.
13. Connect the fuel lines.
14. Install the glow plug bracket.
15. Install the glow plug relay.




16. Connect the glow plug relay electrical connectors (1, 2, 3).




17. Install the charged air cooler inlet duct to the turbocharger.
18. Align the mark on the duct (2) with the mark on the turbocharger.
19. Position the clamp (1) as shown for proper clearance.

Tighten
Tighten the clamp to 6 N.m (53 lb in).

20. Install the bolt attaching the positive battery cable junction box and bracket.




21. Install the inlet hose to the water outlet tube.
22. Install the inlet hose to the radiator.
23. Reposition the inlet hose clamps.
24. Drain the cooling system.
25. Connect the negative battery cables.
26. Replace all hold down ties.
27. Start the engine and check for leaks or noises.
28. After the engine warms up, refill the coolant reservoir to the proper level.