3
FUEL RAIL, INJECTOR LINE & STOCK PLENUM REMOVAL
CAUTION: Cleanliness cannot be overemphasized when handling or replacing
diesel fuel system components. This especially includes the fuel injectors, high-
pressure fuel lines and fuel injection pump. Very tight tolerances are used with
these parts. Dirt contamination could cause rapid part wear and possible
plugging of fuel injector nozzle tip holes. This in turn could lead to possible
engine misfire.
Before assembly, examine each part for dirt, grease or other contaminants and
clean if necessary. When installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
1. Disconnect the battery negative cables.
2. Remove the charge air cooler outlet tube connection from the intake manifold.
3. Remove the engine oil dipstick tube mounting bolt.
4. If needed, remove dipstick support at fuel filter housing.
5. Disconnect the air grid heater power cable at the cable mounting stud.
Caution!!!
If a grid heater will
not
be re-installed this wire
must
also be disconnected at
the relay on the passenger side battery tray to avoid a short circuit!!!
6. Remove the engine wiring harness support bolt from the intake manifold.
7. Remove the six (6) intake manifold mounting bolts.
8. Remove the intake manifold.
9. Remove the high pressure fuel lines and fuel rail.
CAUTION: When loosening or tightening high-pressure lines at the cylinder head,
use a back-up wrench on the crossover tube nut at the head. Do not allow fitting
to rotate. Loss of crossover tube torque will result.
10. When removing fuel line at No. 6 cylinder, a bracket (1) is located above fuel line
connection at cylinder head. Two bolts secure this bracket to rear of cylinder head.
The upper bolt hole is slotted. Loosen (but do not remove) these 2 bracket bolts. Tilt
bracket down to gain access to No. 6 fuel line connection.
NOTE:
It is possible to remove only lines 1-4 and gently flex the rail up high enough
to remove the stock intake plenum/grid heater. Caution must be used to not bend
the number 5 & 6 injector lines if this method is used!!!
