Aerostar 2WD V6-245 4.0L (1990)
Fuel Injection Supply Manifold Assembly: Service and Repair
REMOVAL
1.
Thoroughly clean the engine.
2.
Release pressure from fuel system at fuel pressure relief valve (Schrader) on fuel rail assembly. To gain access to fuel pressure relief valve, valve
cap must first be removed.
3.
Remove the upper intake manifold assembly as outlined in this section.
4.
Disconnect the fuel supply line fitting at the fuel manifold.
5.
Disconnect the fuel return line from the fuel pressure regulator as follows:
a. Disengage the locking tabs on the connector retainer and separate the retainer halves.
b. Inspect the visible internal portion of the fitting for dirt accumulation. Clean the fitting before disassembly.
c. To disengage the fitting from the regulator, push the fitting toward the regulator, insert the finger on fuel line coupling key, into the slots in the
coupling.
d. Using the tool, pull the fitting from the regulator.
NOTE: If the fitting has been properly disengaged, the fitting should slide off the regulator with minimum effort.
6.
Remove the six Torx(R) head stud bolts retaining the fuel manifold and remove the manifold.
7.
Remove the injectors from the fuel supply manifold and wipe cup clean with a clean, dry cloth.
INSTALLATION
1.
Make sure the injector caps are clean and free of contamination. Inspect injector o-rings. Replace if required.
CAUTION:
Do not attempt to clean the injector pintle or metering orifice with brushes or tools.
2.
Carefully wipe the injector recesses in the manifold and make sure they are free of contamination. Lightly grease the recesses.
CAUTION:
Do not use silicone grease to lubricate o-rings. Silicone grease can plug injectors.
3.
Locate the three injectors on the RH side recesses of the intake manifold. Then locate the three on the left.
4.
Position the fuel supply manifold and press down firmly until the injectors are fully seated in the fuel supply manifold and lower intake manifold.
The fuel supply manifold should be fully seated on the lower intake manifold.
5.
Install the six Torx(R) head stud bolts and tighten. Refer to SPECIFICATIONS.
6.
Install the fuel supply line and tighten the fitting to 20-24 N-m (15-18 ft. lb)
7.
Install the fuel return line to the fuel pressure regulator by pushing it onto the fuel pressure regulator line up to the shoulder on the regulator line.
CAUTION:
The connector should grip the regulator line securely.
Fuel Pressure Regulator
8.
Install the connector retainer and snap the two halves of the retainer together.
9.
Install the upper intake manifold as detailed in this section.
10. After the upper intake manifold has been install and before the fuel injector wire connectors have been connected, turn the key to the "ON" position.
This will cause the fuel pump to run for 2-3 seconds and pressurize the system.
11. Using a clean paper towel, check for leaks where the fuel injector is installed into the fuel rail.
12. Install the injector wire connectors and the vacuum line to the regulator.
13. Install the air inlet tube from the throttle body to the air cleaner.
14. Start the engine and let it idle for two minutes.
15. Turn the engine off and check for fuel leaks where the fuel injector is installed in the fuel manifold and the intake manifold.
