Aztek, Rendezvous 2001-2005

Fuel Injectors

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Removal & Installation



3.4L 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:

    Negative battery cable
     
    Upper intake manifold
     
    Engine fuel feed pipe at the fuel rail
     
    Fuel return line from the regulator
     
    Main injector harness and individual injector electrical connectors
     
    Electrical harness from the fuel rail
     
    Coolant Temperature Sensor (CTS) electrical connector
     
    Fuel rail retaining bolts
     
    Fuel rail
     
    Fuel injector retaining clips and injectors
     
    O-rings and discard them

    Click image to see an enlarged view

    Fig. Fuel injector-3.4L engine

     

  6.  

To install:


NOTE
When replacing the fuel injector O-rings install the brown O-ring in the lower position. The lower O-ring uses a nylon collar to properly position it on the injector. Be sure to install the O-ring backup or the sealing O-ring may move when the injector is installed to the fuel rail. If the sealing ring is not seated properly, a vacuum leak is possible thus causing drivability complaints.

  1. Install or connect the following:

    Upper O-ring to the fuel injector
     
    Lower O-ring backup to the injector
     
    Lower O-ring to the injector
     
    Fuel injector to the fuel rail
     
    Fuel rail into the intake manifold. Tilt the rail to install the injectors.
     
    Fuel rail retaining bolts. Torque the bolts to 89 inch lbs. (10 Nm).
     
    CTS electrical connector
     
    Injector electrical harness
     
    Injector electrical connectors. Make sure to push the slide locks into position.
     
    Main injector harness connector
     
    Fuel feed and return pipe, using new O-rings
     
    Fuel feed pipe. Torque the nut to 13 ft. lbs. (17 Nm).
     
    Fuel return pipe to the pressure regulator. Torque the nut to 13 ft. lbs. (17 Nm).
     
    Upper intake manifold
     
    Negative battery cable
     

  2.  
  3. Prime the fuel system as follows:
    1. Turn the ignition switch ON for two seconds.
    2.  
    3. Turn the ignition switch OFF for 10 seconds.
    4.  
    5. Turn the ignition switch ON and checks for leaks. Repair if necessary.
    6.  

  4.  

3.6L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the upper intake manifold.
  6.  
  7. Remove the fuel pipe retaining clip.
  8.  
  9. Use compressed air in order to remove debris from the area where the fuel injectors enter the 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.



    Click image to see an enlarged view

    Fig. Fuel rail removal-3.6L engine

  12.  
  13. Remove the fuel rail with the fuel injectors.

    Click image to see an enlarged view

    Fig. Squeeze the tabs (1) and pull up (2) to disconnect the injector wiring-3.6L engine

  14.  
  15. Disengage the fuel injector electrical connector lock.
  16.  
  17. Disconnect the fuel injector electrical connector.
  18.  
  19. Remove the fuel injector retainer clip.

    Click image to see an enlarged view

    Fig. Fuel injector retaining clip-3.6L engine

  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. Engage the fuel injector electrical connector lock.
  10.  
  11. Install the fuel rail with the fuel injectors.
  12.  
  13. Install the fuel rail bolts. Tighten the fuel rail bolts to 89 inch lbs. (10 Nm).
  14.  
  15. Install the upper intake manifold.
  16.  

 
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