Tools Required

J 39664 Manifold Cover Set

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

Important: Clean all the line fittings that will be loosened or removed.

1. Remove the negative battery cables.
2. Remove the intake manifold. Refer to Upper Intake Manifold Replacement and Lower Intake Manifold Replacement in Engine Mechanical - 6.5L.

Important: Before any further service work is to be done, cover the intake ports with the J 39664 .

3. Remove the injection line clips at the loom brackets.
4. Remove the injection lines at the nozzles.

•	Cap the lines and the nozzles immediately.

•	Do not bend the injection lines.

5. Remove the injection lines at the pump. Refer to Fuel System Description .

•	Cap the lines and the pump fittings immediately.

•	Tag the lines for installation.

1. Install the injection lines at the pump. Refer to Fuel System Description .

•	Uncap the lines and pump fittings.

•	Refer to the tags for the correct installation.

•	Install the injection lines at the nozzles.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Uncap the lines and the nozzles.

Tighten
Tighten the fittings to 25 N·m (18 lb ft).

3. Install the injection line clips at the loom brackets.
4. Remove the J 39664 manifold cover set.
5. Install the intake manifold. Refer to Upper Intake Manifold Replacement and Lower Intake Manifold Replacement in Engine Mechanical - 6.5L.
6. Install the negative battery cables.