Montana SV6 (2006), Relay, Terraza, Uplander (2005-2007)

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. Refer to the fuel system relief procedure in this section.
    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.

  4.  
  5. Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.
  6.  
  7. Remove or disconnect the following:
    WARNING
    Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.


    WARNING
    If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel.



    Fuel feed pipe retaining clip
     
    Fuel feed pipe from the fuel rail
     
    Evaporative emission (EVAP) pipe from the EVAP canister purge solenoid valve
     
    Upper intake manifold
     
    Fuel injector harness from the fuel rail
     
    Coolant temperature sensor and camshaft position sensor electrical connectors
     
    Main fuel injector electrical connector
     
    Fuel rail retaining bolts
     
    Fuel rail assembly
     



    Fuel injector retaining clip
     
    Fuel injector from the fuel rail
     
    Fuel injector upper O-ring
     
    Fuel injector lower O-ring

    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector

     

  8.  

To install:

Click image to see an enlarged view

Fig. Indicating the fuel injector ID number


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

  1. Lubricate the new injector O-ring seats with engine oil.
  2.  
  3. Install or connect the following:
    WARNING
    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.



    Fuel injector upper O-ring
     
    Fuel injector lower O-ring
     
    Fuel injector to the fuel rail
     
    Fuel injector retaining clip
     



    Fuel injector nozzles into the lower intake manifold injector bores
     
    Press on the fuel rail using the palms of both hands until the fuel injectors are fully seated
     
    Install the fuel rail attaching bolts and tighten the bolt to 89 inch lbs. (10Nm)
     
    Injector electrical harness to the fuel rail
     
    Fuel injector electrical connectors
     
    Coolant temperature sensor and camshaft position sensor electrical connectors
     
    Main fuel injector electrical harness connector
     
    Engine fuel feed pipe to the fuel rail
     
    EVAP pipe to the EVAP canister purge solenoid valve
     
    Upper intake manifold
     
    Negative battery cable
     

  4.  
  5. Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks.
  6.  

3.9L Engine
  1. Relieve the fuel system pressure. Refer to the fuel system relief procedure in this section.
    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.

  2.  
  3. Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.
  4.  
  5. Disconnect the fuel supply pipe from the fuel rail.
  6.  
  7. Disconnect any remaining electrical connectors.
  8.  
  9. Remove the upper intake manifold.
  10.  
  11. Remove the fuel injector harness connector bracket bolt from the intake manifold.
  12.  
  13. Disconnect the camshaft position (CMP) sensor electrical connector.
  14.  
  15. Remove the fuel rail mounting bolts.
  16.  
  17. Remove the fuel rail.

    Click image to see an enlarged view

    Fig. Fuel rail mounting-3.9L engine shown

  18.  
  19. Remove the and discard the O-rings from the spray tip end of each injector.
  20.  
  21. Remove the fuel injector retaining clip.
  22.  
  23. Remove the fuel injector from the fuel rail.
  24.  
  25. Remove and discard the fuel injector upper O-ring.
  26.  

To install:


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

  1. Lubricate the new injector O-ring seats with engine oil.
  2.  
  3. Install the new fuel injector upper O-ring.
  4.  
  5. Install each fuel injector to the fuel rail.
  6.  
  7. Install each fuel injector retaining clip.
    WARNING
    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.

  8.  
  9. Lubricate the new lower injector O-ring with clean engine oil.
  10.  
  11. Install the fuel rail assembly into the intake manifold. Tilt the fuel rail assembly slightly to install the injectors.
  12.  
  13. Install the fuel rail mounting bolts and tighten to 89 inch lbs. (10 Nm).
  14.  
  15. Connect the CMP sensor electrical connector.
  16.  
  17. Position the fuel injector harness connector bracket to the intake manifold.
  18.  
  19. Install the fuel injector harness connector bracket bolt. Tighten to the bolt to 71 inch lbs. (8 Nm).
  20.  
  21. Install the upper intake manifold.
  22.  
  23. Connect any remaining electrical connectors.
  24.  
  25. Connect the fuel supply pipe to the fuel rail.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks.
  30.  

 
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