Fuel Rail: Service and Repair

REMOVAL
2. Perform fuel charging system pre-service and fuel pressure release procedures. Pre-Service Procedures
1. Remove air cleaner outlet tube.
3. Disconnect vacuum line from fuel pressure regulator.
4. Remove spring lock coupling retainer clip from fuel supply and return fittings.

NOTE: The following items should be noted when service is required.
- Use specified tool or equivalent.
- Inspect for missing or damaged O-rings.
- Use the specified fuel resistant (Brown) O-rings.
- Lubricate the O-ring with clean engine oil.
- Make sure that the fitting is locked.

5. Using Spring Lock Coupling Disconnect Tool D87L-9280-A (3/8 in) or D87L-9280-B (1/2 inch). Disconnect the fuel supply and return hoses from the fuel injection supply manifold.
6. Disconnect fuel charging wiring from fuel injectors.
7. Remove four fuel injection supply manifold retaining bolts.

NOTE: It may be easier to remove fuel injectors with the fuel injector supply manifold as an assembly.

8. Carefully disengage fuel injection supply manifold from fuel injectors and remove fuel injection supply manifold.
9. Use a rocking, side-to-side motion while lifting to remove fuel injectors from fuel injection supply manifold.

INSTALLATION

CAUTION: When installing fuel injection supply manifold, pay particular attention to proper seating of the fuel injector O-rings to make sure that no fuel leaks exist.

1. Push fuel injection supply manifold down to make sure all fuel injector O-rings are fully seated in the fuel injection supply manifold cups and intake manifold runner control assemblies.
2. Install retaining bolts while holding down fuel injection supply manifold. Tighten bolts to 8-12 Nm (71-106 lb in).
3. Install inlet and outlet fuel lines at spring lock coupling.
4. Connect vacuum line to fuel pressure regulator.
5. Connect fuel charging wiring to injectors.
6. Install air cleaner outlet tube. Tighten engine air cleaner tube clamps to 2.5-3.2 Nm (22-28 lb in).
7. Perform fuel charging post-service procedures. Post-Service Procedures