Removal And Installation

REMOVAL 

1. Disconnect and isolate the negative battery cable.
2. Remove and discard the high pressure fuel pipe. Refer to LINES, FUEL, REMOVAL AND INSTALLATION .

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3. Disconnect the wire harness connections (1) from the fuel injectors.

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4. Remove the bolts (1a) securing the fuel rail (1b) to the cylinder head.

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5. Using the (special tool #2044500140, Remover, Fuel Rail), remove the fuel rail (1a) and injectors (1b).

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6. If required, remove the fuel pressure sensor (1).

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7. Remove the injector fastening pin retaining clips (1).

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8. Remove the injector (1b) fastening pins (1a).

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9. Remove the fuel injector (1a) from the fuel rail (1b).
   NOTE:

   The O-rings (a) and injector seal (b) must be replaced once they have been removed. The O-rings and injector seals should never be reused.

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10. Remove the O-rings (1) from the injectors.

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11. With the (special tool #2025505140, Pliers, Injector Seal Removal) (1a) partially remove the injector seal (1b).

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12. Finish removing the injector seal using the (special tool #2025504140, Pick, Injector Seal 90 Degree) (1a) and the (special tool #2025506140, Pliers, Injector Seal Side Cutter) (1b).
13. Repeat for all of the other injectors.

INSTALLATION 

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1. Lubricate the threads of the fuel rail pressure sensor (1) with a medium hydraulic oil Mobil DTE-25 or equivalent.
2. Install the engine fuel pressure sensor and tighten it the proper specification. Refer to TORQUE SPECIFICATIONS  .
3. Install the NEW  O-rings on each injector.
4. Install the NEW  injector seals on each injector, using the (special tool #2025500140, Kit, Fuel Injector) as described below.

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5. Insert the injector seal (1a) on the (special tool #2025501141, Cone, Injector Seal Installer 70mm) (1b) mounted on the injector (1c).
6. Using the (special tool #2025502140, Installer, Injector Seal to Cone) (2a), slide the injector seal into the recess on the fuel injector (2b).

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7. Check that the injector seal is correctly fitted onto the injector (1a) with the (special tool #2025503140, Tool, Injector Seal Calibration) (1b). The tool has to install and remove freely without catching on the injector seal edge.
8. Lightly lubricate new O-ring seals with engine oil, install the injectors in the fuel rail, insert the fastening pins and engage the respective retaining clips.

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9. Install and hand tighten the (special tool #2044400140, Guide, Fuel Rail Installer) (1) onto the cylinder head.
10. Lightly lubricate new O-ring seals with engine oil, using the fuel rail guides, install the fuel rail (2) and injectors.

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11. Tighten the bolts (1a) securing the fuel rail (1b) to the cylinder head, to the proper specification. Refer to TORQUE SPECIFICATIONS  .
12. Connect the wire harness connections to the injectors and engage the wiring.
13. Install the NEW  high pressure fuel pipe. Refer to LINES, FUEL, REMOVAL AND INSTALLATION .
14. Connect the negative battery cable.
15. Check the high pressure fuel system for leaks. Refer to DIAGNOSIS AND TESTING  .