Removal Procedure
- Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
- Remove the intake plenum. Refer to Intake Plenum Replacement in Engine Mechanical-3.0L (L81).
- Disconnect the fuel rail intermediate lines, supply-return. Then position the fuel rail intermediate lines away from the fuel rail .
- Remove the fuel rail bracket bolts near the fuel supply-return lines.
- Disconnect the fuel injector electrical connectors. Unclip the harness from the fuel rail and position it out of the way.
- Disconnect the fuel pressure regulators atmospheric vent hose.
- Remove the fuel rail attaching bolts from the intake manifold.
- Use compressed air in order to blow dirt out of the area where the injectors enter the intake casting.
- Remove the fuel rail assembly.
- Remove the retainers from the fuel injectors.
- Remove the injectors from the fuel rail.
- Remove the O-rings from the injectors. Discard the O-rings.
Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
Important: Mask off the intake ducts after removing the upper plenum. Entry of foreign objects can cause severe engine damage.
Notice:
• Remove the fuel rail assembly carefully in order to prevent damage
to the injector electrical connector terminals and the injector spray tips.
Support the fuel rail after the fuel rail is removed in order to avoid damaging
the fuel rail components. • Cap the fittings and plug the holes when servicing the fuel system
in order to prevent dirt and other contaminants from entering open pipes and
passages.
Caution: Wear safety glasses when using compressed air in order to prevent eye injury.
Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.
Installation Procedure
- Lubricate the new injector O-rings with clean engine oil.
- Install the new injector O-rings on the injectors.
- Install the injectors to the fuel rail with the new retainer clips.
- Ensure that the injectors are aligned by orienting the electrical connectors perpendicular to the crankshaft centerline.
- Install the fuel rail with the injectors to the intake manifold.
- Install the fuel rail attaching bolts to the intake manifold.
- Reconnect the fuel pressure regulators atmospheric vent hose.
- Reconnect the fuel injector electrical connectors and the clip harness to the fuel rail.
- Install the fuel rail bracket bolts near the fuel supply-return lines.
- Reconnect the fuel rail supply and return lines.
- Reinstall the intake plenum. Refer to Intake Plenum Replacement in Engine Mechanical-3.0L (L81).
- Connect the negative battery cable.
- Crank the engine for a few seconds. Turn OFF the engine if the engine starts.
- Check for fuel leaks.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten
Tighten the fuel rail attaching bolts to 8 N·m (71 lb in).
Tighten
Tighten the fuel rail bracket bolts to 8 N·m (71 lb in).
Tighten
Tighten the lines to 15 N·m (11 lb ft).
