Engine Compartment

REMOVAL PROCEDURE

TOOLS REQUIRED
J 37088-A tool set, Fuel Pipe Quick-Connect Separator

NOTE: Do not attempt to repair the engine fuel feed pipe or the engine fuel return pipe. Replace a damaged engine fuel teed pipe or the engine fuel return pipe.




1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure relief Procedure.
2. Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.
3. Disconnect the quick-connect fittings in the engine compartment.
4. Plug the chassis fuel feed pipe and the chassis fuel return pipe as required.
5. Remove the upper intake manifold assembly.




6. Remove the engine fuel return pipe from the fuel pressure regulator. Discard the O-ring.




7. Remove the engine fuel feed pipe from the fuel rail. Discard the O-ring.

INSTALLATION PROCEDURE




1. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel return pipe to the fuel pressure regulator.

NOTE: Refer to Fastener Notice in Service Precautions.




2. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel feed pipe to the fuel rail.

Tighten
Tighten the engine fuel pipe fittings to 17 N.m (13 lb ft).




3. Install the upper intake manifold assembly.
4. Connect the quick-connect fittings in the engine compartment.
5. Reconnect the fuel tank filler pipe cap.
6. Install the negative battery cable.
6.1. Turn the ignition switch ON for 2 seconds.
6.2. Turn the ignition switch OFF for 10 seconds.
6.3. Turn the ignition switch ON.
6.4. Check for fuel leaks.