Fig. 13 Fuel Injector Wiring Clip

Fig. 14 Fuel Rail Removal

(10)Place intake manifold gasket on lower manifold. Put upper manifold into place and install bolts finger tight.

(11)Install the alternator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts. (Do not tighten.)

(12)Following the tightening sequence in Figure 11, tighten intake manifold bolts to 28 NIm (250 in. lbs.) torque.

(13)Tighten alternator bracket to intake manifold bolt to 54 NIm (40 ft. lbs.) torque (Fig. 13).

(14)Tighten the cylinder head to intake manifold strut bolts to 54 NIm (40 ft. lbs.) torque (Fig. 8).

(15)Connect ground strap, MAP and heated oxygen sensor electrical connectors.

(16)Connect vacuum harness to intake plenum. Connect PCV system hoses.

(17)Using a new gasket, connect the EGR tube to

the intake manifold plenum. Tighten screws to 22 NIm (200 in. lbs.) torque.

(18)Clip wiring harness into the hole in the throttle cable bracket.

(19)Connect electrical connectors to the throttle position sensor (TPS) and Automatic Idle Speed (AIS) motor.

(20)Connect vacuum harness to throttle body.

(21)Install the direct ignition system (DIS) coils. Tighten fasteners to 12 NIm (105 in. lbs.) torque.

(22)Install fuel hose quick connectors fittings to chassis tubes. Refer to Fuel Hoses, Clamps and

Quick Connect Fittings in the Fuel Delivery Section of this Group. Push the fittings onto the chassis tubes until they click into place. Pull on the fittings to ensure complete insertion. Fuel supply fitting is 5/16 inch and fuel return fitting is 1/4 inch.

(23)Install throttle cable.

(24)Install air cleaner and hose assembly.

(25)Connect negative cable to battery.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.

(26) With the ignition key in ON position, access the DRB II ASD Fuel System Test to pressurize the fuel system. Check for leaks.

FUEL PRESSURE REGULATOR

REMOVAL

(1)Perform fuel system pressure release procedure before attempting any repairs. Refer to Fuel Pressure Regulator Procedure in this section.

(2)Remove fuel pressure regulator vacuum connector. (Fig. 15).

(3)Remove regulator retainer screw (Fig. 15).

(4)Remove the fuel pressure regulator retainer (Fig. 15).

WARNING: PLACE A SHOP TOWEL UNDER FUEL PRESSURE REGULATOR TO ABSORB ANY FUEL SPILLAGE.

(5) Remove fuel pressure regulator and O-rings (Fig. 16).