Pacifica 2006-2008

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:

    Negative battery cable
     
    Intake manifold plenum and cover opening with a clean cloth
     

  6.  
  7. Tag the injectors to match them with their correct cylinder during installation.
  8.  
  9. Place a shop rag under the fuel rail-s quick-connect fitting; then, squeeze the quick-connect fitting-s retainer tabs together and pull the fitting assembly off of the fuel tube nipple.

    Fuel injector electrical connectors
     
    Fuel rail-to-engine bolts and fuel rail
     
    Fuel injector-to-fuel rail retainer clips
     
    Fuel injectors

    Click image to see an enlarged view

    Fig. Fuel rail mounting-3.5L engine

     

  10.  

To install:

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

    Fuel injector and secure with retaining clips

    Click image to see an enlarged view

    Fig. Installed view of the fuel injectors-3.5L engine

     
    Fuel rail onto cylinder head and press rail into place. Make sure that the injectors are fully seated.
     
    Fuel rail-to-cylinder head bolts and torque bolts to 250 inch lbs. (28 Nm)
     
    Fuel injector electrical connectors
     
    Intake plenum
     

  4.  
  5. Lubricate the quick-connect fitting-s O-rings with clean engine oil; then, push the connector together until the retainer seats and a click is heard.
  6.  
  7. Connect the negative battery cable.
  8.  

3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the air cleaner housing and inlet hose.
  6.  
  7. Remove the engine cover.
  8.  
  9. Disconnect the Throttle Position (TP) sensor connector.
  10.  
  11. Disconnect the Idle Air Control (IAC) valve connector.
  12.  
  13. Disconnect the purge line.
  14.  
  15. Disconnect the throttle and cruise control cables, if equipped.
  16.  
  17. Disconnect the Manifold Absolute Pressure (MAP) sensor connector.
  18.  
  19. Disconnect the vacuum lines.
  20.  
  21. Remove the Exhaust Gas Recirculation (EGR) tube.
  22.  
  23. Remove the upper intake manifold.
  24.  
  25. Disconnect the injector electrical connectors.
  26.  
  27. If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder.
  28.  
  29. Remove the 4 mounting bolts from the fuel rail.
  30.  
  31. Disconnect the fuel supply line from the fuel rail.
  32.  
  33. Lift fuel rail straight up off of cylinder head.
  34.  
  35. Remove the retaining clips from fuel injectors at the fuel rail.
  36.  
  37. Remove the fuel injector from fuel rail.
  38.  

To install:

Click image to see an enlarged view

Fig. Proper positioning of the fuel injector in the fuel rail-3.8L engine

  1. Inspect and replace any damaged fuel injector O-rings.
  2.  
  3. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
  4.  
  5. Install retaining clips on fuel.
  6.  
  7. Install the fuel injector locator flange on fuel rail.
  8.  
  9. Push the injectors into the fuel injector rail until the clips are in the correct position.
  10.  
  11. Position the fuel rail over the cylinder heads, and push the rail into place. Tighten the fuel rail mounting bolts to 250 inch lbs. (28 Nm).
  12.  
  13. Connect the electrical connectors to the fuel injectors.
  14.  
  15. Connect the fuel supply tube quick connect fitting to the fuel rail.
  16.  
  17. Install the upper intake manifold.
  18.  
  19. Connect and electrical connection for the MAP sensor.
  20.  
  21. Connect the vacuum lines.
  22.  
  23. Connect the electrical connectors to the TPS and IAC.
  24.  
  25. Connect the purge line.
  26.  
  27. Install all remaining components.
  28.  
  29. Connect the negative cable to battery.
  30.  

4.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air cleaner hose from the throttle body.
  8.  
  9. Use a fuel release tool and disconnect the quick connect fuel line from the fuel rail.
  10.  
  11. Remove the upper intake manifold.
    NOTE
    Mark the fuel injector electrical harness connectors with the correct corresponding cylinder numbers.

  12.  
  13. Disconnect the fuel injector electrical connectors.
  14.  
  15. Remove the fuel rail mounting bolts from the fuel rail.
  16.  
  17. Lift the fuel rail straight up off of the cylinder heads.
  18.  
  19. Remove the retaining clips from the fuel injectors at the fuel rail.
    NOTE
    When replacing individual injectors, each injector must be installed in its original position. Mark each injector to identify the correct cylinder.

  20.  
  21. Remove the injectors from the fuel rail.
  22.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Inspect and replace any damaged fuel injector O-rings.
  4.  
  5. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
  6.  
  7. Tighten the fuel rail retaining bolts to 20 ft. lbs.
    CAUTION
    Make sure that the fuel line quick connector is connected properly. Failure to connect the line properly may result in a fuel leak at the rail assembly. Fuel leaked on to a hot engine may ignite resulting to damage to the vehicle.

  8.  
  9. Use a scan tool to pressurize the fuel system.
  10.  
  11. Start the engine and check for leaks, correct as required.
  12.  

 
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