High Pressure Diesel Fuel Injection Rail Replacement

Single Use Fasteners and Components Exhaust Gas Recirculation Cooler Inlet Pipe Gasket Exhaust Gas Recirculation Pipe Seal High Pressure Diesel Fuel Feed to Rail Pipe High Pressure Diesel Fuel Feed to Injector Pipe

Warning

Refer to Diesel/Gasoline Vapors Warning.

Warning

Refer to Safety Glasses Warning. Removal Procedure

1. Turn OFF the engine for 30 seconds before proceeding. This will purge the fuel pressure from the complete fuel system.
2. Plenum Front Panel Outer Reinforcement » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation

High Pressure Diesel Fuel Injection Rail Replacement — figure 1

3. Intake Manifold Cover Bolt (1) » Remove
4. Oil Filler Cap » Remove
5. Intake Manifold Cover (2) » Remove
6. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.

High Pressure Diesel Fuel Injection Rail Replacement — figure 2

7. Air Cleaner Outlet Duct Clamp (1) » Loosen [2x]
8. Air Cleaner Outlet Front Duct (2) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 3

9. Air Cleaner Outlet Duct Clamp (1) » Loosen
10. Air Cleaner Outlet Duct (2) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 4

11. Remove the 3 engine wiring harness bracket nuts (1).
12. Position the rear engine wiring harness channel (2) out of the way.

High Pressure Diesel Fuel Injection Rail Replacement — figure 5

13. Engine Coolant Outlet Pipe Bracket Bolt (1) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 6

Note

Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

14. Remove the 2 exhaust gas recirculation cooler bolts (1).

High Pressure Diesel Fuel Injection Rail Replacement — figure 7

15. Remove the turbocharger coolant feed and return pipe bolt (3) and position the turbocharger coolant feed pipe (2) out of the way.

High Pressure Diesel Fuel Injection Rail Replacement — figure 8

16. Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
17. Remove the exhaust gas recirculation pipe bolt (2).

High Pressure Diesel Fuel Injection Rail Replacement — figure 9

18. Remove the 2 exhaust gas recirculation pipe bolts (1).

High Pressure Diesel Fuel Injection Rail Replacement — figure 10

19. Remove the exhaust gas recirculation pipe (1).
20. Remove and DISCARD the exhaust gas recirculation pipe seal (2).
21. Remove and DISCARD the exhaust gas recirculation cooler inlet pipe gasket (3).

High Pressure Diesel Fuel Injection Rail Replacement — figure 11

22. Disconnect the nitrogen oxides sensor electrical connector.
23. Electrical Connector (1) @ Charge Air Cooler » Disconnect [2x]
24. Wiring Harness Retainer (2) @ Charge Air Cooler » Remove [3x]

High Pressure Diesel Fuel Injection Rail Replacement — figure 12

25. Wiring Harness Retainer (4) @ Charge Air Cooler » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 13

26. Charge Air Cooler Outlet Air Hose Clamp (1) » Loosen until disengaged [2x]
27. Charge Air Cooler Outlet Air Hose (2) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 14

28. Charge Air Cooler Inlet Air Hose Clamp (1) » Loosen until disengaged [2x]
29. Charge Air Cooler Inlet Air Hose (2) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 15

30. Charge Air Cooler Bolt (1) » Remove [4x]

High Pressure Diesel Fuel Injection Rail Replacement — figure 16

31. Charge Air Cooler (1) » Reposition

High Pressure Diesel Fuel Injection Rail Replacement — figure 17

32. Upper Intake Manifold Brace Nut (1) » Remove [3x]
33. Reposition the upper intake manifold bracket (2) with the nitrogen oxides sensor.

High Pressure Diesel Fuel Injection Rail Replacement — figure 18

34. Turbocharger Heat Shield Bolt (1) » Remove [2x]
35. Turbocharger Heat Shield Nut (2) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 19

36. Turbocharger Heat Shield (1) » Reposition

High Pressure Diesel Fuel Injection Rail Replacement — figure 20

37. Release the retaining spring (1).
38. Intake Manifold Resonator (2) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 21

39. Turbocharger Bracket Bolt (1) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 22

40. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
41. Engine Wiring Harness Bracket (3) » Reposition

High Pressure Diesel Fuel Injection Rail Replacement — figure 23

42. Oil Filler Tube Support Stud (1) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 24

43. Engine Coolant Air Bleed Hose Clip (1) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 25

44. Charge Air Cooler Bolt (1) » Remove [5x]
45. Charge Air Cooler Bracket (2) » Remove
46. Disconnect electrical connectors, reposition harness and hoses as needed.

High Pressure Diesel Fuel Injection Rail Replacement — figure 26

47. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Remove
48. Exhaust Gas Recirculation Pipe Bracket (5) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 27

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death. 49. Camshaft Housing Cover Insulator (1) » Remove 50. Front Wheelhouse Liner - Left Side » Remove — Front Wheelhouse Liner Replacement

High Pressure Diesel Fuel Injection Rail Replacement — figure 28

51. Fuel Feed Pipe Clip Bolt (1) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 29

52. Fuel Pump Fuel Feed Hose (1) » Reposition

High Pressure Diesel Fuel Injection Rail Replacement — figure 30

53. Diesel Fuel Separator Bracket Bolt (1) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 31

54. Diesel Fuel Separator (1) » Reposition

High Pressure Diesel Fuel Injection Rail Replacement — figure 32

55. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel pump.

High Pressure Diesel Fuel Injection Rail Replacement — figure 33

56. Remove the 2 fuel feed pipe clip bolts (1).

High Pressure Diesel Fuel Injection Rail Replacement — figure 34

57. Remove the 2 fuel feed pipe clip bolts (1).
58. Unclip the fuel injector fuel return pipe retainer (2).

High Pressure Diesel Fuel Injection Rail Replacement — figure 35

59. Fuel Injection Fuel Return Pipe Retainer (1) » Disengage
60. Fuel Injection Fuel Return Pipe (2) @ High Pressure Diesel Fuel Injection Rail » Disconnect

High Pressure Diesel Fuel Injection Rail Replacement — figure 36

61. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel injection rail.

High Pressure Diesel Fuel Injection Rail Replacement — figure 37

Note

Do NOT reuse the high pressure diesel fuel feed pipes.

62. Remove the high pressure diesel fuel feed to rail pipe (2) from the vehicle and DISCARD.

High Pressure Diesel Fuel Injection Rail Replacement — figure 38

63. Remove the fuel injection fuel feed pipe bracket bolt (1).
64. Remove the fuel injection fuel feed pipe bracket (2).

High Pressure Diesel Fuel Injection Rail Replacement — figure 39

65. Loosen the 12 high pressure diesel fuel feed pipe nuts (1) from the fuel injector and the fuel injection rail.

High Pressure Diesel Fuel Injection Rail Replacement — figure 40

Note

Do NOT reuse the high pressure diesel fuel feed pipes.

66. Remove and DISCARD the 6 high pressure diesel fuel feed to injector pipes (2).

High Pressure Diesel Fuel Injection Rail Replacement — figure 41

67. Disconnect the intake air pressure and temperature sensor electrical connector.
68. Intake Air Pressure and Temperature Sensor Bolt (1) » Remove
69. Intake Air Pressure and Temperature Sensor (2) » Remove

High Pressure Diesel Fuel Injection Rail Replacement — figure 42

70. Disconnect the high pressure diesel fuel sensor (1) and fuel pressure regulator (2) electrical connectors.

High Pressure Diesel Fuel Injection Rail Replacement — figure 43

71. Disconnect and remove the glow plug wiring harness (1).

High Pressure Diesel Fuel Injection Rail Replacement — figure 44

72. Remove the 3 high pressure diesel fuel injection rail nuts (1).

High Pressure Diesel Fuel Injection Rail Replacement — figure 45

73. Remove the high pressure diesel fuel injection rail (1). Cleaning and Inspection Procedure - Required

High Pressure Diesel Fuel Injection Rail Replacement — figure 46

1. Inspect the charge air cooler inlet air hose (2): 1.1. Use dish soap and water to clean the inside of the charge air cooler inlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces. 1.2. Inspect the interior of the charge air cooler inlet air hose (2) for tears or delamination. Replace the hose if damage is found. 1.3. Inspect the charge air cooler inlet air hose clamps (1). Replace the charge air cooler inlet air hose (2) if damage is found or the clamp components are missing.

High Pressure Diesel Fuel Injection Rail Replacement — figure 47

2. Inspect the charge air cooler outlet air hose (2): 2.1. Use dish soap and water to clean the inside of the charge air cooler outlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces. 2.2. Inspect the interior of the charge air cooler outlet air hose (2) for tears or delamination. Replace the hose if damage is found. 2.3. Inspect the charge air cooler outlet air hose clamps (1). Replace the charge air cooler outlet air hose (2) if damage is found or the clamp components are missing. Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

High Pressure Diesel Fuel Injection Rail Replacement — figure 48

Note

DO NOT soak or submerge the fuel rail or injectors in solvent.

1. Clean the exterior of the high pressure diesel fuel injection rail (4) and high pressure diesel fuel injectors in solvent.

2. Inspect the high pressure diesel fuel injection rail (4) and components for the following conditions: 2.1. Damage, debris, or restrictions to the high pressure diesel fuel injection rail (4). 2.2. Damage, debris, or restrictions to the fuel ports (2) at the high pressure diesel fuel injection rail (4). 2.3. Damage to the mounting area or threads on the high pressure diesel fuel injection rail  (4). 2.4. Damage to the holes of the high pressure diesel fuel sensor (1) and fuel pressure regulator (3). Installation Procedure

3. Install the high pressure diesel fuel injection rail (1).

Caution

Refer to Fastener Caution.

2. Fuel Injection Fuel Rail Nut (1) » Install and tighten [3x] — Fastener Specifications

3. Install and connect the glow plug wiring harness (1).

4. Intake Air Pressure and Temperature Sensor (2) » Install

5. Intake Air Pressure and Temperature Sensor Bolt (1) » Install and tighten — Fastener Specifications

6. Connect the intake air pressure and temperature sensor electrical connector.

7. Connect the high pressure diesel fuel sensor (1) and fuel pressure regulator (2) electrical connectors.

8. Install NEW high pressure diesel fuel feed to injector pipe(s) (2).

9. Hand tighten the high pressure diesel fuel feed to injector pipe fittings (1).

Caution

Refer to Component Fastener Tightening Caution.

10. Tighten the high pressure diesel fuel feed to injector pipe fittings (1). Fastener Specifications

11. Install the fuel injection fuel feed pipe bracket (2).

12. Install the fuel injection fuel feed pipe bracket bolt (1) and tighten. Fastener Specifications

13. Install a NEW high pressure diesel fuel feed to rail pipe (2)

14. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel injection rail.

15. Fuel Injection Fuel Return Pipe (2) @ High Pressure Diesel Fuel Injection Rail » Connect

16. Fuel Injection Fuel Return Pipe Retainer (1) » Install

17. Install the 2 fuel feed pipe clip bolts (1) and tighten. Fastener Specifications

18. Attach the fuel injector fuel return pipe retainer (2).

19. Install the 2 fuel feed pipe clip bolts (1) and tighten. Fastener Specifications

20. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel pump.

21. Tighten the high pressure diesel fuel feed to rail pipe fittings to both the high pressure diesel fuel pump and the high pressure diesel fuel injection rail. Fastener Specifications

22. Diesel Fuel Separator (1) » Install

23. Diesel Fuel Separator Bracket Bolt (1) » Install and tighten — Fastener Specifications

24. Fuel Pump Fuel Feed Hose (1) » Install

25. Fuel Feed Pipe Clip Bolt (1) » Install and tighten — Fastener Specifications

26. Front Wheelhouse Liner - Left Side » Install — Front Wheelhouse Liner Replacement

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death. 27. Camshaft Housing Cover Insulator (1) » Install

28. Exhaust Gas Recirculation Pipe Bracket (5) » Install

29. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Install and tighten — Fastener Specifications

30. Reposition harness, hoses, and connect electrical connectors as needed.

31. Charge Air Cooler Bracket (2) » Install

32. Charge Air Cooler Bolt (1) » Install and tighten [5x] — Fastener Specifications

33. Engine Coolant Air Bleed Hose Clip (1) » Install

34. Oil Filler Tube Support Stud (1) » Install and tighten — Fastener Specifications

35. Engine Wiring Harness Bracket (3) » Install

36. Engine Wiring Harness Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

37. Turbocharger Bracket Bolt (1) » Install and tighten — Fastener Specifications

38. Intake Manifold Resonator (2) » Install

39. Engage the retaining spring (1).

40. Turbocharger Heat Shield (1) » Install

41. Turbocharger Heat Shield Nut (2) » Install and tighten — Fastener Specifications

42. Turbocharger Heat Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

43. Instal the upper intake manifold bracket (2) with the nitrogen oxides sensor.

44. Upper Intake Manifold Brace Nut (1) » Install and tighten [3x] — Fastener Specifications

45. Charge Air Cooler (1) » Install

46. Charge Air Cooler Bolt (1) » Install and tighten [4x] — Fastener Specifications

47. Charge Air Cooler Inlet Air Hose (2) » Install

48. Charge Air Cooler Inlet Air Hose Clamp (1) » Tighten [2x] — Fastener Specifications

49. Charge Air Cooler Outlet Air Hose (2) » Install

50. Charge Air Cooler Outlet Air Hose Clamp (1) » Tighten [2x] — Fastener Specifications

51. Connect the nitrogen oxides sensor electrical connector.

52. Wiring Harness Retainer (4) @ Charge Air Cooler » Install

53. Wiring Harness Retainer (2) @ Charge Air Cooler » Install [3x]

54. Electrical Connector (1) @ Charge Air Cooler » Connect [2x]

55. Install a NEW exhaust gas recirculation cooler inlet pipe gasket (3).

56. Install a NEW exhaust gas recirculation pipe seal (2).

57. Install the exhaust gas recirculation pipe (1).

High Pressure Diesel Fuel Injection Rail Replacement — figure 49

Note

Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

58. Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).

59. Exhaust Gas Recirculation Outlet Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications.

60. Exhaust Gas Recirculation Outlet Pipe Bolt (2) » Install and tighten — Fastener Specifications

61. Install the turbocharger coolant return hose clip (1).

62. Install and tighten the turbocharger coolant feed and return pipe bolt (3). Fastener Specifications

Note

Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

63. Exhaust Gas Recirculation Cooler Bolt (1) » Install and tighten [2x] — Fastener Specifications.

64. Engine Coolant Outlet Pipe Bracket Bolt (1) » Install and tighten — Fastener Specifications

65. Install the rear engine wiring harness channel (2).

66. Install the 3 engine wiring harness bracket nuts (1) and tighten. Fastener Specifications

67. Air Cleaner Outlet Duct (2) » Install

68. Air Cleaner Outlet Duct Clamp (1) » Tighten — Fastener Specifications

69. Air Cleaner Outlet Front Duct Air Cleaner Outlet Duct Clamp (2) » Install

70. Air Cleaner Outlet Duct Clamp (1) » Tighten [2x] — Fastener Specifications

71. Oil Filler Cap » Remove

72. Intake Manifold Cover (2) » Install

73. Intake Manifold Cover Bolt (1) » Install and tighten — Fastener Specifications

74. Oil Filler Cap » Install

75. Plenum Front Panel Outer Reinforcement » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

76. Perform the high pressure fuel variable reset. High Pressure Fuel Variable Reset

77. Prime the fuel system and inspect for leaks. Fuel System Priming

78. Check for exhaust leak.