B. Install Fuel Rail Seals

1. If the engine is equipped with an intake manifold cover (1996 and early-1997 3.8L engines only), remove the cover and set it aside.





2. Using the provided Scotch-Brite pad, clean any dirt or white oxide build-up from the fuel rail area near the crossover tube joints (Figure 2). Clean both of the crossover tube joints with the Scotch-Brite pad and then use compressed air to remove any remaining particles.

3. Install the two provided clamps around the crossover tube. Start the clamps for 1-2 turns to ease seal installation.

4. Lightly lubricate the rubber material of the four fuel rail seal halves with clean engine oil. Be sure to coat the flat ends as well as the two beads.

IMPORTANT:
Drain any excess oil from the seals.





5. Install two of the seal halves around the front fuel rail crossover tube joint (Figure 3).

NOTE:
Both of the seal halves are identical.





6. Seat the seal halves around the joint and then while holding the two seals halves together, install one of the provided clamps around the seal halves (Figure 4).

7. Tighten the clamp to 75 in-lbs (8.5 N.m).

8. Install the remaining two seal halves around the rear fuel rail crossover tube joint (Figure 3).

9. Seat the seal halves around the joint and then while holding the two seals halves together, install the other clamp around the seal halves (Figure 4).

10. Tighten the clamp to 75 in-lbs (8.5 N.m).

11. If the engine was equipped with an intake manifold cover (1996 and early-1997 3.8L only), the cover must be modified as follows:





a. Remove the spring clip from the cover that was attached to the fuel rail near the crossover tube joint (Figure 5). Discard the clip.

b. Using a small cut-off wheel, saw or similar tool, remove the plastic cover material inside of the mold line on the end of the cover (Figure 5).

c. Reinstall the cover onto the intake manifold. Tighten the cover bolt securely.

12. No further action is necessary. Return the vehicle to the customer.