Fuel Injector: Service and Repair

WARNING: Fuel system pressure must be released prior to any service of fuel injection components.

NOTE: Tag injector electrical connectors for proper cylinder identification.

NOTE: Intake manifold plenum must be removed before fuel injectors can be replaced.

REMOVAL
1. Disconnect the negative battery cable.
2. Remove intake manifold plenum.

Fuel Supply Tubes 3.5L:

3. Disconnect fuel supply and return tubes from fuel rail. Use shop towels to soak up any fuel that was spilled.
4. Remove injector electrical connectors.
5. Remove fuel pressure regulator vacuum tube.

Fuel Injector Clamp:

6. Remove fuel rail mounting bolts.

Fuel Injector Clamp:

7. Remove injector clamp screw.

Fuel Injector Clamp Removal/Installation:

8. Slide injector clamp toward rear of engine, and remove.
9. Install fuel rail mounting bolts finger tight.

Fuel Injector Removal:

10. Using thin flat blade screwdriver, pry fuel injectors out of fuel rail.
11. Ensure the O-rings were removed with the injector. If not, remove them from fuel rail.


INSTALLATION

NOTE: If fuel rail was removed to service injectors, use a new gasket when installing fuel rail.

1. Before installing injectors lubricate the O-rings with a drop of clean engine oil.

Fuel Injector Alignment 3.5L:

2. Align injector with tab in fuel rail. Install fuel injector.
3. Remove fuel rail mounting bolts.
4. Install fuel injector clamps.
5. Install fuel rail mounting bolts and torque to 100 in-lbs (11 Nm).
6. Install fuel injector clamp screw.
7. Install fuel injector electrical connectors.
8. Install fuel pressure regulator vacuum tube.
9. Connect fuel supply and return tubes from fuel rail. Use shop towels to soak up any fuel that was spilled.
10. Install intake manifold plenum.
11. Connect the negative battery cable.
12. Connect the DRB II scan tool and select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks. SEE COMPUTERS AND CONTROL SYSTEMS/SCAN TOOL ORIENTATION.

CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test.