Fuel Rail: Service and Repair

REMOVAL
1. Perform fuel pressure release procedure. Service and Repair
2. Remove upper intake manifold.
3. Disconnect fuel charging wiring from fuel injectors and position wiring out of the way.
4. Disconnect vacuum line at fuel pressure regulator.
5. Disconnect Intake Manifold Runner Control (IMRC) actuator cable from stud on linkage lever and bracket.
6. Remove spring lock coupling retainer clip from fuel supply and return fittings.
7. Using Spring Lock Coupling Disconnect Tool D87L-9280A (3/8 inch) or D87L-9280B (1/2 inch) or equivalent, disconnect the fuel supply and return hoses from the fuel injection supply manifold.

NOTE: The following items should be noted when service is required:
- Use specified tool or its equivalent.
- Inspect for missing or damaged O-rings.
- Use the specified fuel resistant 0-rings (Brown).
- Lubricate the 0-rings with clean engine oil.
- Check to ensure that the fittings are locked.

8. Remove seven fuel injection supply manifold retaining bolts.

NOTE: It is necessary to remove fuel injectors with the fuel injection supply manifold as an assembly.

9. Remove IMRC linkage rod from lower intake manifold by carefully prying rod with a screwdriver. Replace the IMRC linkage rod bushings prior to reassembly.
10. Carefully disengage fuel injection supply manifold with fuel injectors and remove fuel injection supply manifold and fuel injector seals. Discard the seals.
11. Using Injector Remover T94P-9000AH, remove fuel injectors from fuel injection supply manifold.

INSTALLATION
1. Install fuel injectors into fuel injection supply manifold as outlined.

NOTE: The fuel injector seals must be replaced anytime the fuel injection supply manifold is removed from the intake manifold.

2. Install new fuel injector seals between the fuel injection supply manifold and the lower intake manifold and install the fuel injection supply manifold.
3. Install fuel injector retainers and bolts while holding fuel injection supply manifold down. Verify proper installation of fuel injector retainers and tighten bolts to 8-12 Nm (71-106 lb in).

NOTE: Replace IMRC linkage rod bushings before installing linkage rod.

4. Install IMRC linkage rod to lower intake manifold.
5. Install IMRC actuator cable into bracket and connect cable end to linkage lever.
6. Install spring lock couplings.
7. Connect vacuum line to fuel pressure regulator.
8. Connect fuel charging wiring to fuel injectors.
9. Install upper intake manifold.
10. Install fuel inlet and return couplings to retaining bracket.