G6 2005-2007

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.4L Engine

CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Disconnect the fuel feed line quick connect fitting from the fuel rail.
  8.  
  9. Disconnect the Electronic Throttle Control (ETC) electrical connector.
  10.  
  11. Remove the 2 engine harness clips from the fuel rail tabs.
  12.  
  13. Remove the fuel injector wiring harness electrical connector clip from the intake manifold tab.
  14.  
  15. Disconnect the engine harness electrical connector from the fuel injector harness wiring electrical connector.
  16.  
  17. Remove the fuel rail bolts.
  18.  
  19. Pull the fuel rail back and upward in order to release the fuel injectors from the cylinder head ports.
  20.  
  21. Remove the fuel rail.
  22.  
  23. Remove the fuel injector retainer.
  24.  
  25. Remove the fuel injector from the fuel rail.
  26.  
  27. Remove and discard the fuel injector O-rings
  28.  

To install:

  1. Lubricate the new O-rings with clean engine oil and install the O-rings on the injector(s).
  2.  
  3. Install the fuel injector to the fuel rail.
  4.  
  5. Install the fuel injector retainer.
  6.  
  7. Install the fuel injector wiring harness clips to the fuel rail.
  8.  
  9. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
  10.  
  11. Lubricate the new fuel injector tip insulators with clean engine oil.
  12.  
  13. Install the new fuel injector tip insulators to the cylinder head.
  14.  
  15. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  16.  
  17. Carefully push down on the fuel rail in order to insert the injectors into the cylinder head ports.
  18.  
  19. Install the fuel rail bolts and tighten to 89 inch lbs. (10 Nm).
  20.  
  21. Connect the engine harness electrical connector to the fuel injector wiring harness electrical connector.
  22.  
  23. Install the fuel injector wiring harness electrical connector clip to the intake manifold tab.
  24.  
  25. Install the 2 engine harness clips to the fuel rail tabs.
  26.  
  27. Connect the ETC 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. Start the vehicle, check for leaks and repair if necessary.
  36.  

3.5L & 3.9L Engines

CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the engine fuel feed pipe from the fuel rail.
  6.  
  7. Remove the upper intake manifold.
  8.  
  9. Disconnect the main injector harness electrical connector.
  10.  
  11. Disconnect the main fuel injector electrical harness connector.
  12.  
  13. On 3.9L, disconnect the CMP sensor electrical connector.
  14.  
  15. On all engines, depress the lock tabs and disconnect the fuel injector electrical connectors.
  16.  
  17. Remove the fuel injector electrical wiring harness from the fuel rail.
  18.  
  19. Remove the fuel rail assembly.
  20.  
  21. Remove the fuel injector O-ring seal from the spray tip end of each injector.
  22.  
  23. Remove and discard O-rings if damaged.
  24.  
  25. Remove the fuel injector retainer.
  26.  
  27. Remove the fuel injector from the fuel rail.
  28.  
  29. Remove and discard the fuel injector O-rings
  30.  

To install:

  1. Lubricate the new O-rings with clean engine oil and install the O-rings on the injector(s).
  2.  
  3. Install the fuel rail assembly into the intake manifold. Tilt the fuel rail assembly slightly to install the injectors.
  4.  
  5. Install the fuel rail bolts and tighten to 89 inch lbs. (10 Nm).
  6.  
  7. Install the fuel injector electrical wiring harness to the fuel rail.
  8.  
  9. Connect the fuel injector electrical connectors.
  10.  
  11. Push the slide locks into position.
  12.  
  13. Connect the main fuel injector electrical harness connector.
  14.  
  15. On 3.9L, connect the CMP sensor electrical connector.
  16.  
  17. Install the fuel feed pipe to the fuel rail.
  18.  
  19. Install the upper intake manifold.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Start the vehicle, check for leaks and repair if necessary.
  24.  

3.6L Engine

CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the fuel injector sight shield.
  4.  
  5. Disconnect the engine wiring harness electrical connector from the fuel injector wiring harness electrical connector
  6.  
  7. Disconnect the fuel feed pipe quick connect fitting from the fuel rail. Use fuel line disconnect tool set J 37008-A or equivalent.
  8.  
  9. Remove the upper intake manifold.
    CAUTION
    Wear safety glasses when using compressed air in order to prevent eye injury.

  10.  
  11. Use compressed air in order to remove any debris from the around the area where the fuel injectors enter the lower intake manifold.
  12.  
  13. 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.

  14.  
  15. Remove the fuel rail with fuel injectors from the lower intake manifold.
  16.  
  17. Lift up the fuel injector electrical connector retainer.
  18.  
  19. Push in the fuel injector electrical connector tab in order to disconnect the connector from the injector.
  20.  
  21. Remove the fuel injector retainer clip.
  22.  
  23. Remove the fuel injector.
  24.  
  25. Remove and discard the fuel injector seals.
  26.  

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.

    Click image to see an enlarged view

    Fig. Fuel rail and injector installation-3.6L engine

  12.  
  13. Install the fuel rail bolts and tighten to 89 inch. lbs. (10 Nm).
  14.  
  15. Install the upper intake manifold.
  16.  
  17. Connect the fuel feed pipe quick connect fitting to the fuel rail.
  18.  
  19. Connect the engine wiring harness electrical connector to the fuel injector wiring harness electrical connector.
  20.  
  21. Install the fuel injector sight shield.
  22.  

 
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