Fuel Rail RH

Fuel Rail RH
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures How to Use TAS Procedures

Removal

CAUTION: Make sure that tools and equipment are clean and free of foreign material and lubricant.

CAUTION: Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

NOTE:
Removal steps in this procedure may contain installation details.

NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.
For additional information, refer to Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions
For additional information, refer to Fuel System Pressure Release - 5.0L Service and Repair
1 Disconnect the battery ground cable.
For additional information, refer to Specifications Battery and Charging System
For additional information, refer to Fuel Injection Component Cleaning Fuel Injection Component Cleaning
For additional information, refer to Air Cleaner Outlet Pipe T-Connector Air Cleaner Outlet Pipe T-Connector

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
2 Raise and support the vehicle.

NOTE:
Engine shown removed for clarity.

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

NOTE:
Engine shown removed for clarity.
3 Lower the vehicle.

NOTE:
LH illustration shown, RH is similar.

Special Service Tool

Spark Plug Remover/Installer, 303-1450

CAUTION: Make a note of the fuel injector clamp alignment to the fuel rail prior to removal.

CAUTION: Make sure that the special tool is located correctly to the fuel injector prior to removing the fuel injector.

CAUTION: Make sure that the special tool is held square to the fuel injector during removal.

CAUTION: Make sure that all open ports are covered to prevent any foreign material ingress.

NOTE:
RH illustration shown, LH is similar.

Special Service Tool

Fuel Injector Remover, 310-197

CAUTION: If the fuel injector is being removed without a new component being installed, the fuel injector clamp must remain with the fuel injector it is removed with.

CAUTION: Do not use a knife to remove the Teflon seal as damage could occur to the fuel injector.

CAUTION: Do not cut the Teflon seal to deep as damage could occur to the fuel injector.

CAUTION: Pinch the Teflon seal to allow the tool to cut the Teflon seal without damaging the fuel injector.

CAUTION: Do not use any sharp tools to remove the O-ring seal as damage could occur to the fuel injector.

Installation

Special Service Tool

Teflon seal installer, 310-198

Special Service Tool

Teflon seal re-shape tool, 310-199

CAUTION: If the original fuel injector is being installed, the original fuel injector clamp must installed with the fuel injector it was removed with.

CAUTION: If a new cylinder head has been installed then the special tool 310-200-02 without the thread must be used to install the fuel rail.

NOTE:
LH illustration shown, RH is similar.

Special Service Tool

Fuel Rail Installation Guide Pins - Threaded, 310-200-01

Special Service Tool

Fuel Rail Installation Guide Pins - Unthreaded, 310-200-02

CAUTION: Make sure that the area around the open fuel injector ports are clean and free of foreign material and lubricant prior to installing the fuel injector.

CAUTION: When installing the fuel injector(s), make sure that the Teflon seal is clean and free of foreign material and lubricant.

NOTE:
LH illustration shown, RH is similar.

CAUTION: If new fuel injectors are installed, a new injector clamp must be installed.

CAUTION: Make sure that the fuel injector is aligned and installed into the fuel rail correctly, as noted in the removal step.

CAUTION: Tighten the fuel rail retaining bolts a turn at a time until the correct torque is achieved.

NOTE:
Lubricate the fuel injector O-ring seals with clean engine oil.

NOTE:
LH illustration shown, RH is similar.

Torque to: 20 Nm

NOTE:
LH illustration shown, RH is similar.

Special Service Tool

Fuel Rail Installation Guide Pins - Threaded, 310-200-01

Special Service Tool

Fuel Rail Installation Guide Pins - Unthreaded, 310-200-02

NOTE:
LH illustration shown, RH is similar.

Torque to: 20 Nm

NOTE:
Tighten the bolts in the indicated sequence.

NOTE:
LH illustration shown, RH is similar.
Bolt 2: 30 Nm
Bolt 3: 30 Nm
Bolt 1: 30 Nm
Bolt 4: 30 Nm

Special Service Tool

Spark Plug Remover/Installer, 303-1450

Torque to: 20 Nm

NOTE:
LH illustration shown, RH is similar.

Torque to: 7 Nm

NOTE:
LH illustration shown, RH is similar.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
1 Raise and support the vehicle.

CAUTION: Lubricate only the union threads with clean engine oil.

NOTE:
Engine shown removed for clarity.

NOTE:
Install the bolt and unions finger tight before final tightening.

NOTE:
Remove and discard the blanking caps.
2 Lower the vehicle.

NOTE:
Do not tighten at this stage.

NOTE:
Remove and discard the blanking caps.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
3 Raise the vehicle.

NOTE:
Engine shown removed for clarity.
Unions (1): 21 Nm
M6 (2): 11 Nm
M8 (3): 25 Nm
M5 nut (4): 6 Nm

NOTE:
Engine shown removed for clarity.

Torque to: 21 Nm

NOTE:
Engine shown removed for clarity.
4 Lower the vehicle.

CAUTION: Lubricate only the union threads with clean engine oil.

NOTE:
Do not tighten at this stage.

NOTE:
Remove and discard the blanking caps.

Unions: 21 Nm
Bolts: 8 Nm

Torque to: 21 Nm

For additional information, refer to Air Cleaner Outlet Pipe T-Connector Air Cleaner Outlet Pipe T-Connector
5 Connect the battery ground lead.
For additional information, refer to Specifications Battery and Charging System