Removal Procedure

WARNING:

The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

WARNING:

Refer to Diesel/Gasoline Vapors Warning .

WARNING:

Refer to Safety Goggles and Fuel Warning .

CAUTION:

When working on the fuel rail and fuel injectors, always maintain a clean work surface. Failure to maintain a clean work surface can result in contaminant on the injector seals and cause leaks.

Ignition Coil Replacement - Remove
Fuel Feed Intermediate Pipe Replacement - Remove
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Fuel Injection Fuel Rail Wiring Harness (1) - Disconnect

NOTE:

The fuel rail bolts remain in the fuel rail assembly.

Loosen the 4 fuel rail bolts (2) from the cylinder head completely, but do not remove the bolts.
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NOTE:
Never loosen both bolts at the same time. Failure to follow this could cause leaks or malfunction after installation.

NOTE:
Ensure that the bolt does not fall into the cylinder head slot.

Remove the fuel injector bolt (1) from the fuel injector cylinder 1 (2) at the rail side.
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CAUTION:
Make sure that the correct special tool EN-51146-1-6 demounting screws (long) are used for the continental MGE fuel rail and the EN-51146-150 demounting screws (short) are used for the Delphi fuel rail.

The use of the wrong demounting screws can lead to a damage of the cylinder head.

Match the length of the fuel injector bolts (1, 3) with EN-51146-150 demounting screw (4) and EN-51146-1-6 demounting screw (2).
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CAUTION:
Refer to Fastener Caution .

If the length matches with EN-51146-1-6 demounting screw install the EN-51146-1-6 demounting screw (2) to the EN-51146-1-1 support (1) and tighten to 7 N.m (62 lb in).
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If the length matches with the EN-51146-1-150 demounting screw install the EN-51146-150 demounting screw (2) to the EN-51146-1-1 support (1) and tighten to 7 N.m (62 lb in).
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Install the EN-51146-1-1 support (1) to the fuel injector cylinder 1 (2) and tighten to 5 N.m (44 lb in).
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Remove the fuel injector bolt (1) from the fuel injector cylinder 1 (2).
Install the EN-51146-1-6 demounting screw or EN-51146-150 demounting screw to the EN-51146-1-1 support and tighten to 7 N.m (62 lb in).
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Install the EN-51146-1-1 support (1) to the fuel injector cylinder 1 (2) and tighten to 5 N.m (44 lb in).
Repeat the steps 6 - 10 for the other 3 injectors.
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NOTE:
The fuel rail bolts remain in the fuel rail assembly.

Loosen the 4 fuel rail bolts (1) completely from the cylinder head, but do not remove the bolts.
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NOTE:
The arrow on the EN-51146-100 plate must point towards the front of the vehicle.

Install the EN-51146-100 plate (2) to the 8 EN-51146-1-1 supports (4).
Install the 8 plate bolts (3).
Tighten the 8 plate bolts (3) and counterhold with a wrench (1) at the EN-51146-1-1 supports (4).
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Install the 2 EN-51146-1-3 sliding hammers (1) to the EN-51146-1-2 plate (2).
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NOTE:
Ensure that the fuel injectors are removed from the bore evenly.

Using the EN-51146-1-3 sliding hammers carefully loosen the fuel injector rail assembly.
Remove the fuel injector rail assembly.
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CAUTION:
After removing the fuel rail and injector assembly, do not allow the weight of the assembly to rest on the fuel injectors. Always position the assembly on a clean work surface with the fuel injectors on top. Failure to follow this caution could cause leaks or malfunction after installation.

Install the EN-51146-1-2 plate (1) with the fuel injector assembly to a bench vise (2).
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NOTE:
The EN-51146-2-5 calibration tools are also used to protect the fuel injectors.

Install the 4 EN-51146-2-5 calibration tools (2) to the fuel injectors (1), as shown in the graphic.
Cover the fuel injector bores at the cylinder head, to prevent dirt contamination.
Remove the 2 EN-51146-1-3 sliding hammers.
Remove the 4 EN-51146-2-5 calibration tools.
Inspect all fuel injectors for damage.
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CAUTION:
Always use the stylus from the EN-51146 fuel injector kit. Never use a metal tool in place of the stylus. Use of another tool can damage the fuel injector and may cause a leak.

Remove the 2 combustion seals (2) each fuel injector, use EN-51146-2-1 stylus (1).
Inspect all fuel injectors for damage.