Fuel Manifold (Rail) and Fuel Filter Base – Remove and Install


Fuel Manifold (Rail) 

Removal Procedure

Remove the fuel injection lines.
If necessary, remove the fuel pressure sensor.
The fuel manifold is shown with fuel injection lines in position.


If the fuel sensor (4) has not been removed from the fuel manifold (1), slide the locking tab (3) into the unlocked position. Disconnect the plug on the harness assembly (6) from the fuel pressure sensor (4).
Disconnect the tube assembly (5) from the fuel pressure relief valve on the fuel manifold (1). Immediately cap the open port in the fuel manifold (1) with a new cap. Immediately plug the open end of the tube assembly (5) with a new plug. Remove the three setscrews (2) from the fuel manifold (1).
Remove the fuel manifold (1) from the mounting bracket (7).

Installation Procedure

Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage. Do not install a fuel manifold that has not been capped. All caps must be left in place until the fuel injection lines or the fuel pressure sensor are installed.

The fuel manifold is shown with fuel injection lines in position.
Position the fuel manifold (1) on the mounting bracket (7).
Install the three setscrews (2) to the fuel manifold (1) finger tight.
Install a new set of fuel injection lines and seals.
Tighten the setscrews (2) to a torque of 22 N·m (16 lb ft).
Remove the plug from the tube assembly (5). Remove the cap from the appropriate port in the fuel manifold (1). Connect the tube assembly (5) to the fuel pressure relief valve on the fuel manifold (1).
If the fuel pressure sensor (4) was not removed from the fuel manifold (1), connect the plug on the harness assembly (6) to the fuel pressure sensor (4). slide the locking tab (3) into the locked position.
If the fuel pressure sensor (4) was removed from the fuel manifold (1), install the fuel pressure sensor (4) and a new sealing washer. Remove the air from the fuel system.




Fuel Filter Base (Secondary Fuel Filter)

Removal Procedure

Isolate the fuel supply.
Make temporary identification marks on the plastic tube assemblies (3), (4) and (5) in order to show the correct position of the tube assemblies.


Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled. Clean up any spillage of fuel immediately.

Disconnect the plastic tube assemblies (3), (4) and (5) from the fuel filter base (1). Plug the plastic tube assemblies with new plugs. Cap the ports in the fuel filter base with new caps. Remove the fuel filter.
Remove the two setscrews (2) from the fuel filter base (1). Remove the fuel filter base from the mounting bracket. Do not disassemble the fuel filter base.

Installation Procedure

Ensure that the fuel filter base (1) is clean and free from damage. If necessary, replace the complete fuel filter base and filter assembly.

Position the fuel filter base (1) on the mounting bracket. Install the setscrews (2). Tighten the setscrews to a torque of 44 N·m (32 lb ft).
Remove the plugs from the plastic tube assemblies. Remove the caps from the ports in the fuel filter base.
Ensure that the plastic tube assemblies are installed in the original positions. 

Falture to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Contaminated fuel will cause serious damage to the engine.
Connect the plastic tube assemblies (3), (4) and (5) to the fuel filter base (1).
If necessary, install a new fuel filter (6) to the fuel filter base (1).
Restore the fuel supply. Remove the air from the fuel system.