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Fuel Injector: Installation: 3.8L

Fig 1: Fuel Injector & Clip
GC0000414Courtesy of DAIMLERCHRYSLER CORP.
  1. Inspect and replace damaged fuel injector O-rings. See Figure.
    Fig 2: Fuel Injector O-Ring
    GC0000403Courtesy of DAIMLERCHRYSLER CORP.
  2. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
  3. Install retaining clips on fuel injectors. See Figure.
    Fig 3: Fuel Rail Locator Tabs
    GC0000413Courtesy of DAIMLERCHRYSLER CORP.
  4. Fuel injector locator flange on fuel rail. See Figure.
    Fig 4: Installing Fuel Injector
    GC0000405Courtesy of DAIMLERCHRYSLER CORP.
  5. Push injectors into fuel injector rail until clips are in the correct position. See Figure.
    Fig 5: Fuel Injector Clip
    GC0000412Courtesy of DAIMLERCHRYSLER CORP.
  6. Fuel injector installed into fuel rail in the correct position. See Figure.
    Fig 6: Installing Fuel Injectors
    GC0000404Courtesy of DAIMLERCHRYSLER CORP.
  7. Fuel rail with injectors installed. See Figure.
    Fig 7: Fuel Rail Bolts Locations
    GC0000416Courtesy of DAIMLERCHRYSLER CORP.
  8. Position fuel rail over cylinder heads, and push rail into place. See Figure. Tighten fuel rail mounting bolts to 28 N.m (250 in. lbs.) torque.
    Fig 8: Fuel Injector Wiring Harness
    GC0000417Courtesy of DAIMLERCHRYSLER CORP.
  9. Connect the electrical connectors to the fuel injectors and lock. See Figure.
    Fig 9: Fuel Line Disconnect Fitting
    GC0000407Courtesy of DAIMLERCHRYSLER CORP.
  10. Connect the fuel supply tube quick connect fitting to the fuel rail. See Figure.
    Fig 10: Intake Gaskets Removed
    GC0000409Courtesy of DAIMLERCHRYSLER CORP.
  11. Inspect the intake manifold gaskets. See Figure.
    Fig 11: Installing Intake Gasket
    GC0000410Courtesy of DAIMLERCHRYSLER CORP.
  12. Intake manifold gaskets installed. See Figure.
    Fig 12: Removing Intake Manifold
    GC0000411Courtesy of DAIMLERCHRYSLER CORP.
  13. Install intake manifold plenum. See Figure, (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION) - 3.5L, (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD/UPPER - INSTALLATION) - 3.8L .
    Fig 13: Manifold Absolute Pressure Sensor
    GC0000418Courtesy of DAIMLERCHRYSLER CORP.
    1 - MAP Sensor
    2 - Vacuum Lines
  14. Connect and lock the electrical for the MAP sensor (1).
  15. Connect the vacuum lines (2). See Figure.
    Fig 14: Throttle Body Components
    GC0000419Courtesy of DAIMLERCHRYSLER CORP.
    1 - Purge Line
    2 - Throttle Position Sensor
    3 - Idle Air Control Motor
  16. Connect the electrical connector for Throttle Position Sensor (2), Idle Air Control Motor (3). See Figure.
  17. Connect the purge line (1).
  18. Connect negative cable to battery.
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