Lower Manifold Assembly

Lower Manifold Assembly Removal:

Upper And Lower Manifold Assemblies:

Upper & Lower Manifolds - Parts Legend:

IDENTIFICATION
A label containing the last four digits of the lower manifold assembly identification number appears on the pressure regulator. (The bar code also contains the component number for manifolds, and the four digits of the identifying number.) Refer to this number if servicing or part replacement is required.

Refer to the disassembled view for identification of parts during repair procedures.

TOOLS REQUIRED
J 37088-A Tool Set, Fuel Pipe Quick-Connect Separator

REMOVE OR DISCONNECT
1. Relieve fuel system pressure.
^ Refer to Fuel System / Service and Repair. [1][2]Fuel System Pressure Relief Procedure
2. Negative battery cable.
3. Upper manifold assembly.
4. Quick-connect fittings at engine compartment fuel feed and return pipes:
A. Grasp both ends of one fuel pipe connection and twist 1/4 turn in each direction to loosen any dirt in quick-connect fitting. Repeat for other fitting.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

Clean
Using compressed air, blow out dirt from all quick-connect fittings before removing.

B. Choose correct tool from J 37088-A tool set for size of fitting.
C. Insert tool into female connector, then push inward to release male connector.
D. Repeat for other fitting.

5. Plug fuel feed and return pipes as required.
6. Bolts retaining power steering pump brace, and brace.
7. Engine fuel inlet pipe retainer nuts and retainers.
8. Fuel inlet pipe and seal.
9. Transmission fill tube attaching nut.
10. Lower manifold attaching nuts.
11. Lower manifold.
^ Discard gasket.

CAUTION:
Use care in cleaning old gasket material from machined aluminum surfaces as sharp tools may damage sealing surfaces.

Clean
^ If it is necessary to remove rust or burrs from the male tube end of the fuel feed/return pipes quick-connect fittings, use emery cloth in a circular motion with the tube end to prevent damage to O-ring sealing surface.
^ Gasket mating surfaces.
^ Using a clean shop towel, wipe off male tube end of the fuel feed/return pipes quick-connect fittings. Replace pipes if damaged.

Inspect
^ Replacement lower manifold for items that are to be transferred from unit removed from engine.

Disassemble
^ Exhaust Gas Recirculation (EGR) transfer pipe.
^ Lower manifold and other remaining parts to be transferred following component repair procedures.

Assemble
^ Replacement lower manifold with transferred parts following component repair procedures.
^ Apply pipe sealant to threaded ends of EGR transfer pipe. Install EGR transfer pipe.

Tighten
EGR transfer pipe nuts to 27 Nm (20 lb. ft.).

INSTALL OR CONNECT
^ Position EGR valve injector so that the port faces directly toward the throttle bore.

1. New lower manifold gasket.
2. Position lower manifold on studs.
3. Lower manifold attaching nuts.

Tighten
Lower manifold attaching nuts 30 Nm (22 lb. ft.), using tightening sequence shown in image.

4. Transmission fill tube attaching nut.
5. New fuel inlet pipe O-ring seal.
6. Fuel inlet pipe nut.
^ Finger tighten only.
7. Support nut on bottom of lower manifold.
^ Finger tighten only.

Tighten
Fuel inlet pipe retaining nut to 30 Nm (22 lb. ft.).
Fuel pipe support nut to 10 Nm (89 lb. in.).

8. Power steering pump brace with attaching bolts.

WARNING: To reduce the risk of fire and personal injury, always apply a few drops of clean engine oil to the male tube ends before connecting fuel pipe quick-connect fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)

9. Unplug fuel feed and return pipes.
10. Fuel feed and return line quick-connect fittings:
A. Apply a few drops of clean engine oil to the male tube ends of the engine fuel feed and return pipes.
B. Push connectors together to cause the retaining tabs/fingers to snap into place.
C. Once installed, pull on both ends of each connection to make sure they are secure.
D. Repeat for other fitting.

11. Upper manifold assembly.
12. Tighten fuel filler cap.
13. Negative battery cable.

INSPECT
Turn ignition switch to the "ON" position for two seconds, then turn to the "OFF" position for ten seconds. Again turn to the "ON" position and check for fuel leaks.