Tools Required

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

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

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
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. Refer to Metal Collar Quick Connect Fitting Service .
4. Plug the chassis fuel feed pipe and the chassis fuel return pipe as required.
5. Remove the upper intake manifold assembly. Refer to Intake Manifold Replacement in Engine Mechanical.



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



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

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.

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.




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. 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. Reinstall the upper intake manifold assembly. Refer to Intake Manifold Replacement in Engine Mechanical.
4. Connect the quick-connect fittings in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
5. Tighten the fuel tank filler pipe cap.
6. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
7. Inspect for fuel leaks.

7.1.	Turn the ignition switch ON for 2 seconds.

7.2.	Turn the ignition switch OFF for 10 seconds.

7.3.	Turn the ignition switch ON.

7.4.	Check for fuel leaks.