Fuel Rail - Removal

3.6L

WARNING: The fuel system is under constant pressure even with engine off. Before servicing the fuel rail, fuel system pressure must be released.





1. Perform the fuel pressure release procedure Service and Repair.
2. Disconnect and isolate the negative battery cable (1).





3. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).





4. Disconnect the electrical connector (1) from the Inlet Air Temperature (IAT) sensor.
5. Loosen the clamp (2) at the throttle body.
6. Loosen the clamp (3) at the air cleaner housing.
7. Lift the air inlet hose assembly retaining grommet off the ball stud (4).
8. Remove the air inlet hose assembly (5).





9. Remove the upper intake manifold (2) Intake Manifold - Removal.





10. Remove the insulator (2) from the left cylinder head cover.





11. Disconnect the fuel injector electrical connectors (2).
12. Disconnect the fuel supply hose (1) from the fuel rail Service and Repair.

CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate the rail halves at the connector tube. Due to the design of this tube, it does not use any clamps. Never attempt to install a clamping device of any kind on the tube. When removing the fuel rail assembly for any reason, be careful not to bend or kink the tube.





13. Remove the fuel rail (2) four retaining bolts (1).
14. Lift the fuel rail and the fuel injectors from the lower intake manifold.

CAUTION: When removing the fuel rail from the lower intake manifold, one or more fuel injectors may remain in the intake manifold resulting in residual fuel spilling onto the engine from the fuel rail.





15. If required, remove any remaining fuel injectors (1) from the lower intake manifold.






NOTE: Number 2 fuel injector removal shown, all other fuel injectors similar.

16. If required, remove any remaining fuel injectors (1) from the fuel rail (2).





17. Remove and discard all fuel injector O-ring seals (1).