Fuel Rail - 3.5L GTDI: Installation
- 1.NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
Using the Fuel Injector Brush, clean the fuel injector orifices.
- 2.NOTE: Do not attempt to cut the lower Teflon ® seal without first pulling it away from the fuel injector or damage to the injector may occur.NOTE: Be very careful when removing the lower Teflon ® seals, not to scratch, nick or gouge the fuel injectors.
Pull the lower Teflon ® seal away from the injector with narrow tip pliers.
- 4.NOTE: Do not lubricate the 6 new lower Teflon ® fuel injector seals.
Install the new lower Teflon ® seals on the narrow end of the Arbor (part of the Fuel Injector Seal Installer), then install the Arbor on the fuel injector tips.
- 5.NOTE: Once the Teflon ® seal is installed on the Arbor, it should immediately be installed onto the fuel injector to avoid excessive expansion of the seal.
Using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon ® seals off of the Arbor and into the groove on the fuel injectors.
- 6.
Place the Adjustment Ring (part of the Fuel Injector Seal Installer) beveled side first, over the fuel injector tip until it bottoms out against the fuel injector and turn 180 degrees.- After one minute, turn the Adjustment Ring back 180 degrees and remove.
- 7.NOTE: It is very important to note the routing of the fuel charge wiring harnesses on the fuel rails and index-mark the location of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct fuel charge wire harness routing and tie strap positioning for installation.
Install the fuel charge wire harnesses and tie straps to the index-marked locations on the fuel rails. Start by attaching the first tie strap farthest down the wire harness and continue to the connector end of the harness, leaving ample slack between the fuel injectors.
- 9.NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.NOTE: To install, apply clean engine oil to the 6 new upper fuel injector O-ring seals only. Do not lubricate the lower fuel injector Teflon ® seals.NOTE: Inspect the fuel injector support disks and replace if necessary.
Install the 6 new upper fuel injector O-ring seals.
- 11.NOTE: The anti-rotation device on the fuel injector has to slip into the groove of the fuel rail cup.
Install the 6 fuel injectors into the fuel rails and connect the 6 electrical connectors.
- 12.NOTE: It is very important to visually inspect the routing of the fuel charge wire harness to make sure that they will not be pinched or damaged between the fuel rail and the cylinder head during installation.NOTE: Tighten the bolts in a method that draws the fuel rail evenly to the head, preventing a rocking motion.
Install the 6 new bolts and the RH fuel rail assembly.
- Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and then proceed inward.
- To install, tighten to 10 Nm (89 lb-in).
- Tighten an additional 45 degrees.
- 13.NOTE: It is very important to visually inspect the routing of the fuel charge wire harness to make sure that they will not be pinched or damaged between the fuel rail and the cylinder head during installation.NOTE: Tighten the bolts in a method that draws the fuel rail evenly to the head, preventing a rocking motion.
Install the 6 new bolts and the LH fuel rail assembly.
- Push down on the fuel rail face above the injectors and begin tightening the outer bolts first and proceed inward.
- To install, tighten to 10 Nm (89 lb-in).
- Tighten an additional 45 degrees.
- 14.NOTE: To install, apply clean engine oil to the threads of the 3 high-pressure fuel tube flare nuts.
Install the high-pressure fuel tube and tighten the 3 flare nuts in the following 3 stages.
- Stage 1: Tighten to 32 Nm (24 lb-ft).
- Stage 2: Wait 10 minutes to minimize pre-stress.
- Stage 3: Tighten to 32 Nm (24 lb-ft).
- 17.
Install the intake manifold. For additional information, refer to Engine 3.5L GTDI .
- 18.
Connect the battery ground cable. For additional information, refer to Battery, Mounting and Cables .