Lower Manifold Assembly

Lower Intake Manifold Service:

Tightening Sequence:

REMOVAL PROCEDURE
1. Relieve fuel pressure release procedure.
2. Disconnect the negative battery cable.
3. Remove the upper manifold assembly.
4. Remove the quick-connect fittings at the engine compartment fuel feed and return pipes.
5. Use compressed air in order to blow out dirt from all quick-connect fittings before removal.
6. Grasp both ends of one fuel pipe connection and twist 1/4 turn in each direction in order to loosen any dirt in quick-connect fitting. Repeat this process for the other fitting.
7. Choose the correct tool from J 37088-A tool set for size of fitting.
8. Insert the tool into the female connector. Push inward in order to release the male connector.
9. Repeat for the other fitting.
10. Remove the plug fuel feed and return pipes as required.
11. Remove the bolts retaining the power steering pump brace, and brace.
12. Remove the engine fuel inlet pipe retainer nuts and retainers.
13. Remove the fuel inlet pipe and seal.
14. Remove the transmission fill tube attaching nut.
15. Remove the lower manifold attaching nuts (3).
16. Remove the lower manifold (2). Discard gasket (1)

CAUTION: In order to prevent damage to the sealing surfaces, carefully use sharp tools in cleaning the old gasket from the aluminum surfaces.

17. Whenever 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.
18. Remove the gasket mating surfaces.
19. Using a clean shop towel in order to wipe off the male tube end of the fuel feed/return pipes quick-connect fittings. Replace the pipes if damaged.
20. Inspect the lower manifold for items that are to be transferred to the new manifold.
21. Disassemble the lower manifold and other remaining parts to be transferred following component repair procedures.
22. Assemble the replacement lower manifold with the transferred parts following the component repair procedures.

INSTALLATION PROCEDURE
1. Install the new lower manifold gasket (1).
2. Position the lower manifold (2) on the studs.
3. Install the fuel inlet pipe retaining nut.

Tighten
Retaining nut to 30 NM (22 lb ft).

4. Install the fuel pipe support nut.

Tighten
Nut to 10 Nm (89 lb in).

5. Install the lower manifold attaching nuts (3).

Tighten
Nuts to 30 Nm (22 lb ft), using tightening sequence in image.

6. Install the transmission fill tube attaching nut.
7. Install the new fuel inlet pipe O-Ring seal.
8. Install the fuel inlet pipe nut (Finger tighten only).
9. Support the nut on the bottom of the lower manifold (Finger tighten only).

Caution: In order to reduce the chance of fire and personal Injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-Rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

10. Install the power steering pump brace with the attaching bolts.
11. Unplug the fuel feed and the return pipes.

Important:
- Apply a few drops of clean engine oil to the male tube ends of the engine fuel feed and the return pipes.
- Push the connectors together in order to cause the retaining tabs/fingers in order to snap into place.
- Once installed, pull on both ends of each connection in order to ensure that they are secure.
- Repeat for the other fitting.

12. Install the fuel feed and the return line quick-connect fittings.
13. Install the upper manifold assembly.
14. Tighten the fuel filler cap.
15. Connect the negative battery cable.
16. Inspect for leaks.
1. Turn the ignition switch ON for 2 seconds.
2. Turn the ignition switch OFF for 10 seconds.
3. Turn the ignition switch ON.
4. Check for fuel leaks.