Aurora 2001-2003

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Fuel injector sight shield
     
    Fuel line fittings
     
    Fuel injector electrical connectors
     
    All necessary vacuum hoses
     
    Wiring harness from the fuel rail, if necessary
     
    Fuel rail from the intake manifold by pushing the locking tab away from the center of the intake manifold
     
    Fuel injector from the fuel rail and by spreading the retainer clip to release it

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail assembly-3.5L engine



    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector-3.5L engine

     

  6.  

To install:


WARNING
If the O-rings are different colors, install the black O-ring in the upper position and the brown O-ring in the lower position.

  1. Install or connect the following:
    NOTE
    Position the fuel rail so the electrical connectors may be installed easily



    New O-rings on the fuel injectors
     
    Fuel injector on the fuel rail by pushing the retainer far enough to engage the clip
     



    Fuel rail onto the intake manifold by pushing the locking tab until it locks in place
     
    Wiring harness to the fuel rail, if necessary
     
    All vacuum hoses
     
    Fuel injector electrical connectors
     
    Fuel line fittings
     
    Negative battery cable
     

  2.  
  3. Pressurize the fuel system and check for leaks.
  4.  
  5. Install the fuel injector sight shield. Torque the bolts to 27 inch lbs. (3 Nm).
  6.  

4.0L Engine


Click image to see an enlarged view

Fig. Exploded view of the fuel rail and fuel injector-4.0L engine



Click image to see an enlarged view

Fig. Exploded view of the fuel rail and intake manifold-4.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Air intake duct
     
    Quick-connect fittings at the fuel rail
     
    Fuel pressure regulator and Positive Crankcase Ventilation (PCV) Valve vacuum hoses
     

  6.  
  7. Reposition the coolant surge tank inlet pipe.

    Fuel rail bracket retainer bolt
     
    Fuel injector electrical connectors
     
    Fuel rail bolts
     
    Rail and injectors as an assembly from the manifold
     
    Fuel injector from the fuel rail by spreading the retainer
     
    Fuel injector
     

  8.  

To install:

  1. Lubricate the new O-rings with engine oil.
  2.  
  3. Install or connect the following:

    Fuel injector using a new retainer clip and new O-rings
     
    Rail and injectors as an assembly into the manifold until fully seated
     
    Fuel rail bolts and tighten to 89 inch lbs. (10 Nm)
     
    Fuel injector electrical connectors
     
    Fuel rail bracket retainer bolt and tighten to 89 inch lbs. (10 Nm)
     
    Fuel pressure regulator and PCV vacuum hoses
     
    Coolant surge tank inlet pipe
     
    Quick-connect fittings at the fuel rail
     
    Air intake duct
     
    Negative battery cable
     

  4.  
  5. Pressurize the system and check for leaks.
  6.  

 
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