Fuel Rail: Service and Repair

REMOVAL
1. Perform fuel pressure release procedure.
2. Remove air cleaner outlet tube from throttle body.
3. Remove spring lock coupling retainer clip from fuel inlet and return fittings.
4. Using Spring Lock Coupling Disconnect Tool D876-9280-C (5/8 inch), disconnect the fuel supply and return lines from the fuel injection supply manifold.

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 O-rings (black).
- Lubricate the O-ring with clean engine oil.
- Make sure that the fitting is locked.

5. Disconnect fuel charging wiring from fuel injectors.
6. Disconnect fuel shut off valve solenoid.
7. Remove eight fuel injection supply manifold retaining bolts.
8. Carefully disengage fuel injection supply manifold from fuel injectors and remove fuel injection supply manifold.

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

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

INSTALLATION
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.

CAUTION: When installing fuel injection supply manifold make sure that the fuel injector O-rings are properly seated so that there are not any fuel leaks.

2. Install retaining bolts while holding down fuel injection supply manifold. Tighten retaining bolts to 8-12 Nm (71-106 lb in).
3. Install spring lock coupling.
4. Connect fuel charging wiring to fuel injectors and fuel shut off valve solenoid.
5. Install air cleaner outlet tube. Tighten engine air cleaner tube clamps to 2.5-3.2 Nm (23-28 lb in).
6. Perform Fuel Charging System Post-Service procedures. Post-Service Procedures