Fuel Rail: Service and Repair

Fuel Rail - KV6 - NAS

Service repair no - 19.60.04.99

Remove
1. Disconnect battery earth lead.
2. Remove inlet manifold chamber.
3. Remove underbelly panel.







4. Using a 3/8" socket bar raise ancillary drive belt tensioner and release drive belt from alternator and PAS pump pulleys.







5. Remove nuts and bolts securing alternator.
6. Release alternator and place aside.







7. Note position of coil earth lead, remove 3 nuts and 3 bolts securing ignition coils to LH inlet manifold.
8. Remove ignition coils and position aside.







9. Disconnect clips securing RH injector harness to injector protection cover.
10. Remove 2 bolts securing RH fuel rail to RH inlet manifold.
11. Release clips and disconnect injector multiplugs.







12. Remove 2 bolts securing fuel rail to LH inlet manifold.
13. Release clips and disconnect injector multiplugs.







14. Release injectors from manifolds, raise fuel rail assembly, disconnect 4 clips securing injector harness to fuel rails and move harness aside.







15. Remove fuel rail and discard 'O' rings.


CAUTION: Always fit plugs to open connections to prevent contamination.


Refit
1. Lubricate new 'O' rings with castor oil and fit to injectors.
2. Remove plugs from inlet manifolds.
3. Position injector harness to fuel rail and secure with clips.
4. Position injectors and fuel rail to inlet manifolds
5. Connect multiplugs to injectors.
6. Fit and tighten 4 bolts securing fuel rail to inlet manifold to 9 Nm (7 ft. lbs.).
7. Position ignition coils to LH inlet manifold.
8. Position earth lead, fit nuts and bolts securing ignition coils to LH inlet manifold and tighten to 9 Nm (7 ft. lbs.).
9. Position alternator and secure with nuts and bolts, tighten to 45 Nm (33 ft. lbs.).
10. Using a 3/8" square drive socket bar, raise ancillary drive belt tensioner and fit drive belt to pulleys.
11. Fit underbelly panel.
12. Fit inlet manifold chamber.
13. Connect battery earth lead.