H3 2006

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



3.5L & 3.7L Engines
  1. Relieve the fuel system pressure.
  2.  
  3. Disengage the fuel feed quick connect locking clip.

    Click image to see an enlarged view

    Fig. Disengage the fuel feed quick connect locking clip

  4.  
  5. Disconnect the fuel feed line from the fuel rail.
  6.  
  7. Disconnect the Evaporative Emission (EVAP) purge hose from the following:

    Click image to see an enlarged view

    Fig. Disconnect the EVAP purge hose (1) from the throttle control module (2) and EVAP canister purge solenoid valve (3)



    The throttle control module
     
    The EVAP canister purge solenoid valve
     

  8.  
  9. Remove the intake manifold.
  10.  
  11. Disconnect the fuel injector harness connector from the engine wiring harness electrical connector.

    Click image to see an enlarged view

    Fig. Disconnect the fuel injector harness connector from the engine wiring harness electrical connector

  12.  
  13. Before removal, clean the fuel rail assembly and the cylinder head with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent.
  14.  
  15. Remove the fuel rail bolts.
    CAUTION



    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.
     

  16.  
  17. Remove the fuel rail from the cylinder head.
  18.  

To install:

  1. Lightly lubricate the new lower fuel injector O-ring seals with mineral oil GM P/N 9981704.
  2.  
  3. Install the NEW O-ring seals on the spray tip end of each fuel injector.
  4.  
  5. Position the fuel rail to the cylinder head, inserting the spray tip ends of the fuel injectors.
  6.  
  7. Install the fuel rail bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the fuel injector harness connector to the engine wiring harness electrical connector.
  10.  
  11. Install the intake manifold.
  12.  
  13. Connect the EVAP purge hose to the following:

    The throttle control module
     
    The EVAP canister purge solenoid valve
     

  14.  
  15. Connect the fuel feed line to the fuel rail.
  16.  
  17. Engage the fuel feed quick connect locking clip.
  18.  
  19. Inspect for leaks.
    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, with the engine OFF.
    6.  
    7. Inspect for fuel leaks.
    8.  

  20.  

 
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