Fuel Injection Fuel Rail Assembly Replacement L36

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Important: When servicing the fuel rail assembly, take precautions to prevent dirt and other contaminants from entering the fuel passages. Cap the fittings and plug the holes during servicing.

Important: Always maintain cleanliness when servicing fuel system components.

1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief .
2. Clean the fuel rail assembly and connections.
3. Disconnect the fuel feed (1) and return pipes (2) from the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .



4. Disconnect the vacuum line from the fuel pressure regulator.
5. Remove the ignition coil wires.



6. Disconnect the 6 injector electrical connectors.



7. Remove the fuel rail hold-down bolts.
8. Remove the fuel rail with equal force on both sides of the fuel rail.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.

Notice: 

1. The O-rings must be replaced on all components that are serviced.
2. Lightly oil the fuel injector O-rings with clean motor oil.
3. Place the fuel rail assembly on the intake manifold.
4. Seat the fuel injectors by HAND.

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.

5. Install the fuel rail hold down bolts.

Tighten
Torque the fuel rail hold-down bolts to 10 N·m (89 lb in).




6. Connect the 6 fuel injector electrical connectors.



7. Connect the fuel feed (1) and return (2) pipes to the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .



8. Connect the vacuum line to the fuel pressure regulator.
9. Install the ignition coil wires.
10. Tighten the fuel fill cap.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
12. Inspect for leaks.

12.1.

Turn ON the ignition for 2 seconds.

12.2.

Turn OFF the ignition for 10 seconds.

12.3.

Turn ON the ignition.

12.4.

Inspect for fuel leaks.

13. Install the fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical 3.8L.

Fuel Injection Fuel Rail Assembly Replacement L67

Notice: 

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief .
2. Clean the fuel rail assembly and connections.



3. Disconnect the fuel feed pipe (2) and return pipe (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .



4. Disconnect the vacuum line from the fuel pressure regulator.
5. Remove the ignition coil wires from the coil and retainer clips on top of super charger.
6. Remove the generator brace. Refer to Generator Brace Replacement in Engine Electrical.
7. Remove the bypass valve actuator. Refer to Supercharger Bypass Valve Actuator Replacement .



8. Disconnect the fuel injector electrical connectors.



9. Remove the fuel injector electrical harness clips holding harness to front and the rear of the fuel rail.



10. Remove the engine mount strut bolt and nut from the left engine mount strut.
11. Reposition the wiring harness from the left engine mount strut bracket.



12. Remove the fuel rail hold-down nuts.
13. Remove the fuel rail hold down stud.
14. Remove the fuel rail with equal force on both sides of the fuel rail.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.

Notice: 

1. The O-rings must be replaced on all components that are serviced.
2. Lightly oil the fuel injector O-rings with clean engine oil.
3. Place the fuel rail assembly on the intake manifold.
4. Seat the fuel injectors by HAND.

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.

5. Install the nuts.

Tighten
Tighten the fuel rail hold-down nuts to 10 N·m (89 lb in).

6. Install the fuel rail hold down stud.

Tighten
Tighten the stud to 25 N·m (18 lb ft).




7. Install the wiring harness to the engine mount strut.
8. Install the left engine mount strut bolt and nut.

Tighten
Tighten the nut to 48 N·m (35 lb ft).




9. Install the fuel injector electrical harness clips holding harness to the front and the rear of fuel rail.



10. Connect the 6 fuel injector electrical connectors.
11. Install the bypass valve actuator. Refer to Supercharger Bypass Valve Actuator Replacement .
12. Install the rear generator mounting bracket and generator. Refer to Generator Replacement in Engine Electrical.
13. Install the ignition coil wires to the coil, and the retainer clips to the top of super charger.



14. Connect the vacuum line to the fuel pressure regulator.



15. Connect the fuel feed pipe (2) and return pipe (1) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
17. Inspect for leaks.

17.1.

Turn ON the ignition for 2 seconds.

17.2.

Turn OFF the ignition for 10 seconds.

17.3.

Turn ON the ignition.

17.4.

Inspect for fuel leaks.

18. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical 3.8L.