Fuel rail line removal

Hello,

I would start by disconnecting the battery and then follow this video on how to replace a fuel rail on your truck.

https://youtu.be/XZ_lUwYv_gg

Please let us know if you need anything else to get the problem fixed.

Cheers, Ken

Good morning,

I attached the procedure for removing the upper intake manifold and the fuel rail for you.

It would be a good idea to replace the injectors at the same time.

Let me know if you have any other questions.

Roy

REMOVAL

1. Disconnect the negative battery cable.

2. Remove engine air cleaner intake tube and duct from air cleaner to throttle body.

3. Remove the fuel filler cap to relieve fuel tank pressure.

4. Release pressure from fuel system at fuel pressure relief valve.

5. Remove upper intake manifold.

Fuel Injection Supply Manifold
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6. Disconnect fuel supply and return line retaining clips.

7. Disconnect the fuel chassis inlet and outlet fuel hoses from the fuel supply manifold.

Fuel Injection Supply Manifold
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8. Remove four (two per group) fuel supply manifold retaining bolts.

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

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9. Remove manifold.

Removal

1. Disconnect electrical connectors at idle air control valve (IAC valve) (9F715) throttle position sensor (TP sensor) (9B989) and EGR position sensor.

CAUTION: When disconnecting throttle cable from ball stud, use a screwdriver or similar tool close to the stud and pry slowly. Pulling by hand may damage the cable.

2. Disconnect throttle linkage atthrottle ball. Disconnect AOD (SOL only) orC6 (5.8L only) transmission linkage from throttle body. Remove two bolts securing accelerator cable bracket (9723) to intake. Position accelerator cable bracket with cables out of way.
3. Disconnect upper intake manifold vacuum fitting connections by disconnecting all vacuum lines to vacuum tree vacuum lines to EGR external pressure valve (9F483) and vacuum line to fuel pressure regulator.
4. Disconnect PCV system by disconnecting hose from fitting on rear of upper intake manifold
5. On Econoline vehicles remove the oil fill pipe
6. Remove canister purge line(s) from fitting(s) on throttle body
7. Disconnect water heater lines from the throttle body.
8. Disconnect EGR valve to exhaust manifold tube (9D477) from EGR external pressure valve by removing flange nut.
9. Remove bolt from upper intake support bracket to upper intake manifold.
10. Remove six upper intake manifold retaining bolts.
11. Remove upper intake manifold and throttle body as an assembly from lower intake manifold

Installation

1. Clean and inspect the mounting faces of the lower and upper intake manifolds.
2. Position new gasket on lower intake mounting face. The use of alignment studs may be helpful.
3. Install upper intake manifold and throttle body assembly to lower intake manifold making sure gasket remains in place (if alignment studs are not used).
4. Install six upper intake manifold retaining bolts and tighten to 17-24 Nm (12-18 ft-lb).
5. Install upper intake support bracket to upper manifold attaching bolt.
6. Install EGR valve to exhaust manifold tube. Tighten flange nuts to 34-47 Nm (25-35 ft-lb).
7. Install canister purge lines to fittings on throttle body
8. Connect water heater lines to the throttle body
9. Connect PCV hose to rear of upper intake manifold
10. Install oil fill pipe (Econoline vehicles).
11. Connect vacuum lines to vacuum tree EGR external pressure valve and fuel pressure regulator.
12. Position accelerator cable bracket with cables to upper intake manifold. Install two retaining bolts and tighten to 11-13 N.M (8-10. Ft-lb). Connect throttle cable and transmission cable to throttle body
13. Connect electrical connectors at idle air control valve throttle position sensor and EGR position sensor.
14. If lower intake manifold was removed fill and bleed cooling system as outlined. See: Cooling System > Service and Repair