Service Manual

Fuel Rail ISB, ISBe and QSB (Common Rail [...]
Page 6-92 Section 6 - Injectors and Fuel Lines - Group 06
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Clean and Inspect for Reuse
CAUTION
Internal passages of the fuel rail can only be cleaned
with contact cleaner, Part Number 3824510 or
equivalent. Do not use a parts washer to clean the
fuel rail. Dirt or Contaminants can damage the fuel
system.
Inspect the fuel line connections at the fuel rail for cracks
or scratches.
Inspect the inlets of the high-pressure lines for damaged
sealing surfaces.
Check for loose or damaged pressure sensors and
pressure relief valve.
Replace the fuel rail pressure sensor if damaged. Use the
following procedure in the ISB, ISBe2, ISBe3, ISBe4,
QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL, ISLe3,
ISLe4, and QSL9, CM850 Electronic Control System
Troubleshooting and Repair Manual, Bulletin 4021416.
Refer to Procedure 019-115 in Section 19.
Replace the pressure relief valve if it is damaged or
leaking. Refer to Procedure 006-061 in Section 6. When
replacing a fuel rail, the new fuel rail will come with the
pressure sensor and relief valve installed.
Install
Install the fuel rail on the engine.
Hand-tighten the fuel rail capscrews.
Hand-tighten the holding bracket capscrews to loosely fit
the high-pressure pump to fuel rail line to the cylinder
block.
Connect the high-pressure supply line to the high-
pressure fuel pump and high-pressure fuel rail.
NOTE: Apply a counter-torque on the high-pressure pump
outlet port to prevent overtightening.
Torque Value:
3.9L and 5.9L High-Pressure Supply Line
Step 1 30 N•m [ 22 ft-lb ]
Torque Value:
4.5L and 6.7L High-Pressure Supply Line
Step 1 36 N•m [ 27 ft-lb ]
Tighten the high-pressure fuel line holding bracket
capscrews
Torque Value: 24 N•m [ 212 in-lb ]