Fuel Injector - Installation

3.5L





NOTE: Inspect each O-ring seal on all the fuel injectors, replace O-ring seals if any damaged is noted. Note the fuel injector O-rings are color coded. The Blue colored O-ring is for the fuel rail side and the Green colored O-ring is cylinder head side.

NOTE: If individual fuel injectors are being replaced, return the remaining fuel injectors to the original positions noted during removal.

1. Install and lubricate each fuel injector O-rings (1), (3) with a light drop of clean engine oil.
2. Install all of the fuel injectors (2) to the fuel rail (4), then install the retaining clip (5) to the fuel rail (4).




3. Inspect each fuel injector for proper installation. Note how the retaining clip (3) secures the fuel injector (1) to the fuel rail (2).




CAUTION: The fuel rail bolts are actually lower intake manifold bolts. These bolts must be torqued in a mandatory torque sequence.

4. Insert fuel injector nozzles into openings in the cylinder heads. Seat the injectors in place. Install the fuel rail bolts and tighten bolts in a mandatory torque sequence to 28 Nm (20.5 ft. lbs.).
5. Correctly position and connect the fuel injector electrical harness connectors to the fuel injectors.




CAUTION: Make sure the fuel line quick connector is connected properly. Failure to connect the fuel line correctly may result in a fuel leak at the rail assembly. Fuel leaked onto a hot engine may ignite resulting in damage to the vehicle.

6. Connect quick connect fuel line to fuel rail.




7. Connect all fuel injector electrical connectors (1) to fuel injectors (2).




8. Install upper intake manifold, Intake Manifold - Installation.
9. Connect the negative battery cable, tighten the nut to 5 Nm (45 in. lbs.).
10. Use the scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.