Fuel Rail: Removal
WARNING:
Before beginning any service procedure, refer to Safety Warnings in General Information
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.
NOTE:
A clean working environment is essential to prevent dirt or foreign material contamination.
- 1.
Release the fuel system pressure, refer to Fuel System General Information .
- 2.
Disconnect the battery ground cable, refer to Battery, Mounting and Cables .
- 3.
Remove the intake manifold, refer to Engine 2.0L GTDI .
- 4.NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
- 5.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 the fuel injection pump flare nut.
- 7.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, block and general surrounding area of the fuel rail and 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.
- 10.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.
Using the Slide Hammer and the Fuel Injector Remover, remove the fuel injectors that remained in the cylinder head.
- 1.
307-005 (T59L-100-B) or equivalent.
- 2.
310-206.
- 1.
- 11.NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and 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.
- 1.
310-205.
- 1.