Removal Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 5P-0332 | Crowfoot Wrench | 1 |
Start By:
- Remove the fuel pressure relief valve, if necessary. Refer to Disassembly and Assembly, "Relief Valve (Fuel) - Remove and Install".
- Remove the fuel lines. Refer to Disassembly and Assembly, "Fuel Lines - Remove and Install".
| NOTICE |
|---|
Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines. |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| NOTICE |
|---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use. |
 |
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
 |
- Disconnect harness assembly (1) .
 | |
| Illustration 1 | g01444461 |
Note: Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
- Use Tooling (A) in order to remove fuel pressure sensor (2) , if necessary. Discard fuel pressure sensor (2) .
Note: A new fuel rail includes the fuel pressure sensor, the adapter, and the fuel pressure relief valve.
| NOTICE |
|---|
Fuel pressure sensor (2) must only be used once. Discard fuel pressure sensor (2) after use. |
- Remove adapter (3) , if necessary.
- Remove tube assembly (4) from fuel rail (5) .
- Remove bolts (6) and remove fuel rail (5) .
Installation Procedure
| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 5P-0332 | Crowfoot Wrench | 1 |
| B | 161-9203 | Grease Cartridge | 1 |
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| NOTICE |
|---|
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use. |
- Position fuel rail (5) and install bolts (6) . Tighten bolts (6) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
| | |
| Illustration 2 | g01444461 |
- Install tube assembly (4) on fuel rail (5) . Install the fuel lines. Refer to Disassembly and Assembly, "Fuel Lines - Remove and Install".
- Apply Tooling (B) to the threads and face of adapter (3) .
- Install adapter (3) , if necessary. Tighten adapter (3) to a torque of 95 ± 3 N·m (70 ± 2 lb ft).
Note: A new fuel rail includes the fuel pressure sensor, the adapter, and the fuel pressure relief valve.
- Use Tooling (A) in order to install new fuel pressure sensor (2) , if necessary. Tighten fuel pressure sensor (2) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).
- Connect harness assembly (1) .
End By: Install the fuel pressure relief valve, if necessary. Refer to Disassembly and Assembly, "Relief Valve (Fuel) - Remove and Install".