A customer brought me a 2003 with a no start.The hipop wasn't making much pressure-replaced it and the truck started fine but died after warm up.Checked hipop desired and actual pressure,was always lower than desired and percentage was 85% so I figured a leak.Pulled the drivers side valve cover-all the bolts holding the rail down were loose,some backed out halfway.When I removed the bolts,some of them had metal on the threads and sure enough the holes were stripped.The customer bought the truck from an estate,it did run when he first got it.Apparently another shop had studded the heads and either stripped the oil rail bolts or didn't tighten them down.At any rate I will have to helicoil some if not all the holes.I can find a lot of info on the 04 up system,but not much on the early 03.I went ahead and got the HHC leakproof nipple kit.Several questions-besides the nipple cup seals,what all is there to replace as far as seals/orings,etc? What is the torque on the rail bolts? How do I unhook the braided line to the rail? None of my fuel/ac line disconnect tools fit.There is a black plastic ring on the fitting-do I push it in to disconnect? Also,I keep reading about stand pipes and dummy plugs but I don't see anything on this unit.Unfortunately my computer hard crashed on me a few years back and I lost my Alldata and MOD,so I have no reference material at all.

 

The '03 design does not use the dummy plugs, and the standpipes are different, not problematic.

A flat, angle grinder wrench is often used to disconnect the push-on connector used with the '03.

96 lb-in.

 

This is the tool and can probably be found for less at other suppliers. I had to bend it to 90 degrees for clearance to get it on the rear oil line fitting. It slips between the big hex and the black plastic ring on the front fitting.



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