Fuel Rail: Service and Repair

WARNING: Relieve fuel system pressure before disconnecting coupling. Fuel system will remain pressurized after key is off.



REMOVAL
1. To properly relieve fuel system pressure, refer to Fuel Pressure Release/Service and Repair.
2. Remove upper intake manifold.
3. Disconnect fuel supply and return tube retaining clips.
4. Using spring lock coupling disconnect tool, T81P-19623-G1 (3/8 inch) or T81P19623-G2 (1/2 inch), disconnect the fuel chassis inlet and outlet fuel tubes from the fuel injection supply manifold as follows:



a. Fit tool to coupling so that tool can enter cage opening to release the garter spring.
b. Push the tool into the cage opening to release the female fitting from the garter spring.
c. Pull the coupling male and female fittings apart.
d. Remove the tool from the disconnected coupling.



5. Remove four (two per group) fuel injection supply manifold retaining bolts.

NOTE: Fuel injectors will stay in fuel injection supply manifold when removed.



6. Remove fuel injection supply manifold.

INSTALLATION
1. Make sure fuel injector end caps are clean and free of contamination.



2. Install fuel injector into fuel injection supply manifold, then seat fuel injectors into pockets in lower intake manifold. Make sure the fuel injectors are properly seated.

3. Secure the fuel injection supply manifold using four retaining bolts. Tighten to 8-12 N.m (70-105 lb in).
4. Connect the fuel inlet and outlet tubes at the fuel injection supply manifold connections as follows:

a. Check for missing or damaged garter spring, remove damaged spring with small hooked wire, and install new spring.
b. Clean fittings with solvent. Check for missing or damaged O-rings. Replace missing O-rings. If either O-ring is damaged, replace both.
c. Assemble fitting by pushing with a slight twisting motion.
d. To check coupling engagement, pull on fitting and visually check to be sure garter spring is over flared end of female fitting.

5. Connect fuel tube retaining clips.
6. Install upper intake manifold.
7. To properly re-pressurize fuel system refer to Fuel Pressure/Testing and Inspection/Procedures/Fuel Pressure Test.