Fuel Rail — 3.5L GTDI

Special Tool(s)

	Brush, Fuel Injector 310-205
	Remover, Fuel Injector 310-206
	Seal Installer, Fuel Injector 310-207
	Slide Hammer 307-005 (T59L-100-B) or equivalent

Removal

 WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

 WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

 WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

 WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

 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: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. 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. For additional information, refer to Section 310-00 .

2. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

3. Remove the intake manifold. For additional information, refer to Section 303-01B .

4. Remove the fuel injection pump noise insulator shield.

5. Remove the high pressure fuel tube bracket nut.

6. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the flare nuts.

   Loosen the 3 flare nuts and remove the high pressure fuel tube.

7. Disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.

8. NOTICE: It is very important to note the routing of the fuel charge wire harnesses on the fuel rails and index-mark the location of the tie straps prior to removal or damage may occur to the wire harnesses during installation.

   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.

   Cut, remove and discard the fuel charge wiring harness tie straps.

9. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

   NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract.

   Remove and discard the 6 bolts and remove the LH fuel rail.

10. Remove and discard the 6 bolts and remove the RH fuel rail.

11. Disconnect the 6 fuel injector electrical connectors and remove the 2 fuel charge wire harnesses.

12. Remove and discard the 6 upper fuel injector O-ring seals.

13. Remove and discard the 6 fuel injector clips.

14. Using the Slide Hammer and the Fuel Injector Remover, remove the 6 fuel injectors.

Installation

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.

1. 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.

   Using the Fuel Injector Brush, clean the fuel injector orifices.

2. NOTICE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.

   NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

   Pull the lower Teflon® seal away from the injector with narrow tip pliers.

3. Carefully cut and discard the 6 lower fuel injector Teflon® seals.

4. NOTE: Do not lubricate the 6 new lower Teflon® fuel injector seals.

   Install the new lower Teflon® seals on the narrow end of the Arbor (part of the Fuel Injector Seal Installer), then install the Arbor on the fuel injector tips.

5. NOTICE: Once the Teflon® seal is installed on the Arbor, it should immediately be installed onto the fuel injector to avoid excessive expansion of the seal.

   Using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals off of the Arbor and into the groove on the fuel injectors.

6. Place the Adjustment Ring (part of the Fuel Injector Seal Installer) beveled side first, over the fuel injector tip until it bottoms out against the fuel injector and turn 180 degrees.
   • After one minute, turn the Adjustment Ring back 180 degrees and remove.

7. NOTICE: It is very important to note the routing of the fuel charge wiring harnesses on the fuel rails and index-mark the location of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct fuel charge wire harness routing and tie strap positioning for installation.

   Install the fuel charge wire harnesses and tie straps to the index-marked locations on the fuel rails. Start by attaching the first tie strap farthest down the wire harness and continue to the connector end of the harness, leaving ample slack between the fuel injectors.

8. Connect the FRP sensor electrical connector.

9. NOTICE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

   NOTE: To install, apply clean engine oil to the 6 new upper fuel injector O-ring seals only. Do not lubricate the lower fuel injector Teflon® seals.

   NOTE: Inspect the fuel injector support disks and replace if necessary.

   Install the 6 new upper fuel injector O-ring seals.

10. Install the 6 new fuel injector clips.

11. NOTE: The anti-rotation device on the fuel injector has to slip into the groove of the fuel rail cup.

    Install the 6 fuel injectors into the fuel rails and connect the 6 electrical connectors.

12. NOTICE: It is very important to visually inspect the routing of the fuel charge wire harness to make sure that they will not be pinched or damaged between the fuel rail and the cylinder head during installation.

    NOTE: Tighten the bolts in a method that draws the fuel rail evenly to the head, preventing a rocking motion.

    Install the 6 new bolts and the RH fuel rail assembly.
    • Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and then proceed inward.
    • To install, tighten to 10 Nm (89 lb-in).
    • Tighten an additional 45 degrees.

13. NOTICE: It is very important to visually inspect the routing of the fuel charge wire harness to make sure that they will not be pinched or damaged between the fuel rail and the cylinder head during installation.

    NOTE: Tighten the bolts in a method that draws the fuel rail evenly to the head, preventing a rocking motion.

    Install the 6 new bolts and the LH fuel rail assembly.
    • Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and proceed inward.
    • To install, tighten to 10 Nm (89 lb-in).
    • Tighten an additional 45 degrees.

14. NOTE: To install, apply clean engine oil to the threads of the 3 high-pressure fuel tube flare nuts.

    Install the high-pressure fuel tube and tighten the 3 flare nuts in the following 3 stages.
    • Stage 1: Tighten to 32 Nm (24 lb-ft).
    • Stage 2: Wait 10 minutes to minimize pre-stress.
    • Stage 3: Tighten to 32 Nm (24 lb-ft).

15. Install the high-pressure fuel tube bracket nut.
    • Tighten to 8 Nm (71 lb-in).

16. Install the fuel injection pump noise insulator shield.

17. Install the intake manifold. For additional information, refer to Section 303-01B .

18. Connect the battery ground cable. For additional information, refer to Section 414-01 .