Fuel Rail: Service and Repair

Fuel Rail

Service Repair No - 19.60.04

Special Service Tools





Removal
1. Disconnect the battery ground cable.
2. Remove the LH charge air cooler.
3. Disconnect the RH charge air cooler coolant hoses.
^ Position an absorbent cloth to collect fluid spillage.
^ Release the 2 clips.

CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.





4. Remove the RH charge air cooler.
^ Remove the 8 Torx screws.
^ Remove the Torx screw and nut.
^ Discard the gasket.





5. Using the special tool, disconnect the fuel line.
^ Release the clip.
^ Position an absorbent cloth to collect fluid spillage.

WARNING:
^ Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
^ Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
^ The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.





6. Disconnect the fuel temperature sensor electrical connector.





7. Release the fuel injector harness from the fuel rail.
^ Release the 4 clips.





8. Disconnect the fuel injector electrical connectors.
^ Release the 8 clips.





9. Remove the fuel rail.
^ Remove the 4 Torx screws.
^ Remove and discard the fuel injector O-ring seals.





10. Release and remove the fuel injectors
^ Remove the 8 clips.
^ Discard the O-ring seals.

NOTE: Do not disassemble further if the component is removed for access only.





11. Remove the fuel pressure sensor.
^ Remove the 2 bolts.
^ Discard the O-ring seals.





12. Remove the fuel temperature sensor.

CAUTION: To prevent damage to components, use an additional wrench when loosening or tightening unions.





Installation
1. Install the fuel temperature sensor.
^ Clean the component mating faces.
^ Apply sealant to the sensor thread.
^ Tighten the sensor to 7 Nm (5 ft. lbs.).

2. Install the fuel pressure sensor.
^ Clean the component mating faces.
^ Install new O-ring seals.
^ Tighten the bolts to 6 Nm (4 ft. lbs.).

3. Install the fuel injectors to the fuel rail.
^ Clean the component mating faces.
^ Install new O-ring seals.
^ Secure with the clips.

4. Install the fuel rail and injectors.
^ Clean the component mating faces.
^ Install new O-ring seals.
^ Tighten the Torx screws to 10 Nm (7 ft. lbs.).

5. Install the injector harness.
^ Secure the clips.
^ Connect the electrical connectors.

6. Connect the fuel temperature sensor electrical connector.
7. Connect the fuel line to the fuel rail.
^ Clean the component mating faces.
^ Secure the clip.

8. Install the RH charge air cooler.
^ Clean the component mating faces.
^ Install a new gasket.
^ Tighten the Torx screws to 10 Nm (7 ft. lbs.).

9. Connect the charge air cooler coolant hoses.
^ Clean the component mating faces.
^ Secure with the clips.

10. Install the LH charge air cooler.
11. Connect the battery ground cable.