Aura, Outlook 2007

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.4L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Remove the air cleaner outlet duct.
  4.  
  5. Disconnect the fuel feed line quick connect fitting from the fuel rail
  6.  
  7. Disconnect the engine wiring harness electrical connector from the fuel injector wiring harness electrical connector.
  8.  
  9. Disconnect the fuel injector wiring harness electrical from the Manifold Absolute Pressure (MAP) sensor.
  10.  
  11. Remove the engine wiring harness clips from the fuel rail tabs.
  12.  
  13. Remove the fuel rail bolts.
    NOTE
    Use care when removing the fuel rail assembly in order to prevent damage to the fuel injector spray tips.

  14.  
  15. Pull the fuel rail back and upward in order to release the fuel injectors from the cylinder head ports.
  16.  
  17. Remove the fuel rail.
    NOTE
    The fuel injector tip insulators may be located on the injector or may still be located in the cylinder head. Either way, ensure that all 4 injector tip insulators are removed and discarded.

  18.  
  19. Remove and discard the fuel injector tip insulators.
  20.  
  21. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  22.  
  23. Remove the fuel injector wiring harness clips from the fuel rail.
  24.  
  25. Remove the fuel injector wiring harness from the fuel rail.
  26.  
  27. Remove the fuel injector retainer.
  28.  
  29. Remove the fuel injector from the fuel rail.
  30.  
  31. Remove the fuel injector upper O-ring.
  32.  
  33. Remove the fuel injector lower O-ring.
  34.  

To install:


NOTE
The fuel injector assembly is stamped with a part number identification. Be sure to use the correct part number when ordering replacement fuel injectors.

  1. Lubricate the NEW fuel injector O-rings with clean engine oil.
  2.  
  3. Install the NEW fuel injector O-rings.
  4.  
  5. Install the fuel injector to the fuel rail.
  6.  
  7. Install the fuel injector retainer.
  8.  
  9. Install the fuel injector wiring harness clips to the fuel rail.
  10.  
  11. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
  12.  
  13. Lubricate the NEW fuel injector tip insulators with clean engine oil.
  14.  
  15. Install the NEW fuel injector tip insulators to the cylinder head.
  16.  
  17. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  18.  
  19. Carefully push down on the fuel rail in order to insert the injectors into the cylinder head ports.
  20.  
  21. Install the fuel rail bolts. Tighten the bolts to 89 in. lbs. (10 Nm).
  22.  
  23. Install the engine wiring harness clips to the fuel rail tabs).
  24.  
  25. Connect the fuel injector wiring harness electrical to the MAP sensor.
  26.  
  27. Connect the engine wiring harness electrical connector to the fuel injector wiring harness electrical connector.
  28.  
  29. Connect the fuel feed line quick connect fitting to the fuel rail.
  30.  
  31. Install the air cleaner outlet duct.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds
    4.  
    5. Turn ON the ignition
    6.  
    7. Inspect for fuel leaks.
    8.  

  36.  

3.5L Engine

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.


NOTE
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.


NOTE
An 8-digit identification number is stamped on the fuel rail. Refer to this number if servicing or part replacement is required.

  1. Disconnect the fuel feed pipe quick connect fitting from the fuel rail.
  2.  
  3. Remove the upper intake manifold.
  4.  
  5. Disconnect the fuel injector wiring harness electrical connector from the Engine Coolant Temperature (ECT) sensor.
  6.  
  7. Disconnect the fuel injector wiring harness electrical connector from the Camshaft Position (CMP) sensor.
  8.  
  9. Remove the fuel injector wiring harness electrical connector bracket bolt from the intake manifold.
  10.  
  11. Remove the fuel rail bolts.
  12.  
  13. Remove the fuel rail.
  14.  
  15. Remove the fuel injector O-ring seal from the spray tip end of each injector, if the fuel rail was removed for other purposes.
  16.  
  17. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  18.  
  19. Remove the fuel injector wiring harness retainers from the fuel rail.
  20.  
  21. Remove the fuel injector wiring harness.
  22.  
  23. Remove the fuel injector retainers.
  24.  
  25. Remove the fuel injectors.
  26.  
  27. Remove the fuel injector upper and lower O-ring seals.
  28.  

To install:

  1. Lubricate the NEW injector O-ring seals with clean engine oil.
  2.  
  3. Install the NEW fuel injector O-ring seals.
  4.  
  5. Install the fuel injectors.
  6.  
  7. Install the fuel injector retainers.
  8.  
  9. Position the fuel injector wiring harness.
  10.  
  11. Install the fuel injector wiring harness retainers to the fuel rail.
  12.  
  13. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
    NOTE
    Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination. Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components. Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

  14.  
  15. Install NEW fuel injector O-ring seals onto the spray tip end of each injector, if the fuel rail was removed for other purposes.
  16.  
  17. Install the fuel rail.
  18.  
  19. Install the fuel rail bolts. Tighten the bolts to 89 in. lbs. (10 Nm).
  20.  
  21. Align the bracket pin to the hole in the lower intake manifold.
  22.  
  23. Install the fuel injector wiring harness electrical connector bracket bolt to the intake manifold. Tighten the bolt to 10 ft. lbs. (14 Nm).
  24.  
  25. Connect the fuel injector wiring harness electrical connector to the CMP sensor.
  26.  
  27. Connect the fuel injector wiring harness electrical connector to the ECT sensor.
  28.  
  29. Install the upper intake manifold.
  30.  
  31. Connect the fuel feed pipe quick connect fitting to the fuel rail.
  32.  
  33. Connect the negative battery cable. Refer
  34.  
  35. Tighten the fuel fill cap.
  36.  
  37. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds
    4.  
    5. Turn ON the ignition
    6.  
    7. Inspect for fuel leaks.
    8.  

  38.  

3.6L Engine
  1. Remove the fuel injector sight shield.
  2.  
  3. Disconnect the engine wiring harness electrical connector from the fuel injector wiring harness electrical connector.
  4.  
  5. Disconnect the fuel feed pipe quick connect fitting from the fuel rail.
  6.  
  7. Remove the upper intake manifold.
    CAUTION
    Wear safety glasses while using the compressed air to avoid eye injury.

  8.  
  9. Use compressed air in order to remove any debris from the around the area where the fuel injectors enter the lower intake manifold.
  10.  
  11. Remove the fuel rail bolts.
    NOTE
    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.

  12.  
  13. Remove the fuel rail with fuel injectors from the lower intake manifold.
  14.  
  15. Lift up the fuel injector electrical connector retainer.
  16.  
  17. Push in the fuel injector electrical connector tab in order to disconnect the connector from the injector.
  18.  
  19. Remove the fuel injector retainer clip.
  20.  
  21. Remove the fuel injector.
  22.  
  23. Remove and discard the fuel injector seals.
  24.  

To install:

  1. Install NEW fuel injector seals.
  2.  
  3. Install the fuel injector.
  4.  
  5. Install the fuel injector retainer clip.
  6.  
  7. Install the fuel injector electrical connector.
  8.  
  9. Push down on the fuel injector electrical connector retainer, securing the electrical connector.
  10.  
  11. Install the fuel rail with fuel injectors to the lower intake manifold. Tighten the bolts to 89 in. lbs. (10 Nm).
  12.  
  13. Install the upper intake manifold.
  14.  
  15. Connect the fuel feed pipe quick connect fitting to the fuel rail.
  16.  
  17. Connect the engine wiring harness electrical connector to the fuel injector wiring harness electrical connector.
  18.  
  19. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds
    4.  
    5. Turn ON the ignition
    6.  
    7. Inspect for fuel leaks.
    8.  

  20.  
  21. Install the fuel injector sight shield
  22.  

 
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