Fuel Rail Crossover Pipe Replacement

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Disconnect the fuel feed and return pipes (1) from the fuel rail.




3. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
4. Remove the fuel return pipe (1).
5. Remove and discard the fuel return pipe O-ring (6).
6. Remove the fuel pressure connection core assembly (24) from the crossover pipe (25).
7. Remove the retaining clip attaching screw (22) and the crossover fuel pipe retainer clip (21).
8. Remove the retaining clip attaching screw (4) and the crossover fuel pipe retainer clip (5).
9. Remove the crossover pipe rail assembly (25) from the left hand fuel rail assembly (14) and the right hand rail assembly (15).
10. Remove and discard the crossover fuel pipe O-rings (7, 20).

INSTALLATION PROCEDURE




1. Lubricate the NEW crossover fuel pipe O-rings (7, 20) with clean engine oil.
2. Install the NEW crossover fuel pipe O-rings (7, 20) onto the crossover pipe rail assembly (25).
3. Install the crossover pipe rail assembly (25) to the left hand rail assembly (14) and the right hand rail assembly (15).

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the crossover fuel pipe retainer clip (21). Loosely install the retainer clip attaching screw (22).

IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads on the rail.

5. Lubricate the NEW fuel return pipe O-ring (6) with clean engine oil.
6. Install the NEW fuel return pipe O-ring (6) on the fuel return pipe (1).
7. Install the fuel return pipe (1).
8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3).

IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads on the rail.

9. Install the crossover fuel pipe retainer clip (5). Loosely install the retainer clip attaching screw (4).

Tighten
1. Tighten the crossover fuel pipe retainer clip attaching screws (4, 22) to 3.8 N.m (34 lb in).
2. Tighten the fuel return pipe attaching screw (3) to 5 N.m (44 lb in).

3. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25).




4. Connect the fuel feed and return pipes (1) to the fuel rail.
5. Install the fuel fill cap.
6. Connect the negative battery cable.
7. Use the following procedure in order to inspect for leaks:
7.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
7.2. Turn OFF the ignition OFF for 10 seconds.
7.3. Turn ON the ignition ON, with the engine OFF.
7.4. Inspect for fuel leaks.