Lower Manifold Assembly

Upper And Lower Manifold Assemblies:

Upper And Lower Manifold Assembly-Part Name:

Lower Manifold Assembly Removal:

NOTE: 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 part during repair procedures.

REMOVE OR DISCONNECT
1. Relieve fuel system pressure.

- Refer to the Fuel Pressure Relief Procedure. Service and Repair

2. Negative battery cable.
3. Upper manifold assembly.

- Refer to Upper Manifold Assembly. Upper Manifold Assembly

4. Fuel fittings at engine compartment fuel feed and return lines.

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

5. Plug fuel feed and return lines as required.
6. Engine fuel inlet pipe retainer nuts and retainers.
7. Fuel inlet pipe and seal.
8. Lower manifold attaching nuts.
9. Lower manifold.

- Discard gasket.

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

Clean

NOTE: 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 cleaning 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 27.0 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 30.0 Nm (22 lb. ft.), using tightening sequence shown in Figure.

4. New fuel inlet pipe O-ring seal.
5. Fuel inlet pipe nut.

- Finger tighten only.

6. 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.).

7. Unplug fuel feed and return lines.
8. Fuel feed and return line fittings.
9. Upper manifold assembly.

- Refer to Upper Manifold Assembly. Upper Manifold Assembly

10. Tighten fuel filler cap.
11. 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.