Removal Procedure

Warning: Refer to Battery Disconnect Warning in the Preface section.





Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Disconnect the negative battery cable.
2. Disconnect the common rail pressure sensor connector.
3. Disconnect the common rail regulator connector.
4. Disconnect the common rail return hose.
5. Remove the engine wiring guide from the intake manifold.



6. Remove the high pressure fuel pipes. Refer to Fuel Injector Fuel Feed Pipe Replacement.




Note: Put a caps on the common rail pipe threads to avoid contamination from dust as soon as the fuel pipes are removed to prevent be clogged injectors.

7. Remove the common rail assembly.

Caution: Refer to Fastener Caution in the Preface section.





Caution: 

•	Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.

•	Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.

•	Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

Note: Do not reuse the fuel pipes. If reused, the contaminated pipes may be damage the injectors or cause leaks from the pipes.

1. Install the common rail assembly and tighten the retaining bolts to 25 N·m (18.4 lb in).



2. Install the fuel pipes to the common rail. Refer to Fuel Injector Fuel Feed Pipe Replacement.
3. Connect the common rail pressure sensor connector.
4. Connect the common rail regulator connector.
5. Prime the fuel system. Refer to Fuel System Priming.