Fuel Filter
Removal & Installation
Before servicing the vehicle, refer to the Precautions Section.
Relieve the fuel system pressure.
Remove or disconnect the following:
NOTE
To disconnect the quick connector, pull out on the connector while depressing the tab, as shown. Do not use any tools! When connecting, use light engine oil.
Negative battery cable
Fuel filler cap
Fig. Quick connector separation
Fuel lines from the fuel filter Fuel filter
Fig. Fuel filter mounting location under the vehicle
To install:
Install or connect the following:
Fuel filter and tighten the bracket bolt. Note the fuel flow directional arrow. Fuel lines to the fuel filter Negative battery cable
Start the engine and inspect the fuel filter connections for leaks.
Fuel System Service Precautions
Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines:
To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. Always keep a dry chemical (Class B) fire extinguisher near the work area. Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. Always use a backup wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper tightening specifications. Always replace worn fuel fitting O-rings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.
Gasoline Fuel Injection Systems
Adjustments
IDLE SPEED & MIXTURE ADJUSTMENTS
Idle Speed & Mixture Adjustments
Idle speed is maintained by the Powertrain Control Module (PCM). No adjustment is necessary or possible.
Fuel Injectors
REMOVAL & INSTALLATION
Removal & Installation
2.2L Engines
Before servicing the vehicle, refer to the Precautions section.
Relieve the fuel system pressure.
Remove or disconnect the following: Negative battery cableFuel injector harness connectorsPressure regulator vacuum lineFuel linesFuel supply manifold with injectors attachedFuel injector retaining clipsFuel injectors
Negative battery cable Fuel injector harness connectors Pressure regulator vacuum line Fuel lines Fuel supply manifold with injectors attached Fuel injector retaining clips Fuel injectors
To install:
Install or connect the following: Fuel injectors. Use new O-ring seals.Fuel injector retaining clipsFuel supply manifold with injectors attached. Tighten the fasteners to 14 ft. lbs. (19 Nm).Fuel linesPressure regulator vacuum lineFuel injector harness connectorsNegative battery cable
Fuel injectors. Use new O-ring seals. Fuel injector retaining clips Fuel supply manifold with injectors attached. Tighten the fasteners to 14 ft. lbs. (19 Nm). Fuel lines Pressure regulator vacuum line Fuel injector harness connectors Negative battery cable
Start the engine and check for leaks.
3.2L Engines
Before servicing the vehicle, refer to the Precautions section.
Relieve fuel system pressure.
Remove or disconnect the following: Negative battery cableEngine coverFuel injector wiring connectorsFuel linesFuel supply manifold with injectors attachedFuel injector retaining clipsFuel injectors
Negative battery cable Engine cover Fuel injector wiring connectors Fuel lines Fuel supply manifold with injectors attached Fuel injector retaining clips Fuel injectors
To install:
Install or connect the following: Fuel injectors. Use new O-ring seals.Fuel injector retaining clipsFuel supply manifold with injectors attached. Tighten the bolts to 60 inch lbs. (6.5 Nm).Fuel linesFuel injector wiring connectorsEngine coverNegative battery cable
Fuel injectors. Use new O-ring seals. Fuel injector retaining clips Fuel supply manifold with injectors attached. Tighten the bolts to 60 inch lbs. (6.5 Nm). Fuel lines Fuel injector wiring connectors Engine cover Negative battery cable
Start the engine and check for leaks.
3.5L Engine
Before servicing the vehicle, refer to the Precautions section.
Relieve fuel system pressure.
Remove or disconnect the following: Negative battery cableEngine coverFuel injector wiring connectorsFuel linesFuel supply manifold with injectors attachedClipsInjectors from the supply manifold
Negative battery cable Engine cover Fuel injector wiring connectors Fuel lines Fuel supply manifold with injectors attached Clips Injectors from the supply manifold
To install:
Install or connect the following: New O-rings on the fuel injectorsFuel injectorsFuel supply manifold with injectors attached. Tighten the bolts to 60 inch lbs. (6.5 Nm).Fuel linesFuel injector wiring connectorsEngine coverNegative battery cable
New O-rings on the fuel injectors Fuel injectors Fuel supply manifold with injectors attached. Tighten the bolts to 60 inch lbs. (6.5 Nm). Fuel lines Fuel injector wiring connectors Engine cover Negative battery cable
Start the engine and check for leaks.
Fuel Pump
REMOVAL & INSTALLATION
Removal & Installation
1997-03 Models
Before servicing the vehicle, refer to the Precautions Section.
Relieve fuel system pressure.
Drain the fuel tank.
Remove or disconnect the following:
Negative battery cable Fuel filler and vent hoses Fuel tank skid plate Fuel tank wiring connectors Fuel supply and return lines Fuel tank Fuel pump assembly
Fig. Fuel pump assembly mounting
To install:
Install or connect the following:
Fuel pump assembly Fuel tank. Tighten the bolts to 27 ft. lbs. (36 Nm). Fuel supply and return lines Fuel tank wiring connectors Fuel tank skid plate Fuel filler and vent hoses Negative battery cable
Start the engine and check for leaks.
2004 Models
Before servicing the vehicle, refer to the Precautions Section.
Relieve fuel system pressure.
Disconnect the battery ground.
Drain the fuel tank.
Support the tank with a jack.
Disconnect the hoses and wiring at the tank module.
Remove the 5 bolts and one nut securing the tank.
Lower the tank.
Remove the pump unit retainer as shown.
Fig. Removing the pump unit retainer
Installation is the reverse of removal. Use a new seal. Torque the tank bolts and nut to 50 ft. lbs. (68 Nm).
Fuel Rail (Supply Manifold) & Injectors
REMOVAL & INSTALLATION
Removal & Installation
2.2L Engine
Before servicing the vehicle, refer to the Precautions Section.
Relieve the fuel system pressure.
Remove or disconnect the following:
Negative battery cable Fuel injector harness connectors Pressure regulator vacuum line Fuel lines Fuel supply manifold with injectors attached Fuel injector retaining clips Fuel injectors
To install:
Install or connect the following:
Fuel injectors. Use new O-ring seals. Fuel injector retaining clips Fuel supply manifold with injectors attached. Tighten the fasteners to 14 ft. lbs. (19 Nm). Fuel lines Pressure regulator vacuum line Fuel injector harness connectors Negative battery cable
Start the engine and check for leaks.
3.2L Engine
Before servicing the vehicle, refer to the Precautions Section.
Relieve fuel system pressure.
Remove or disconnect the following:
Negative battery cable Engine cover Fuel injector wiring connectors Fuel lines Fuel supply manifold with injectors attached Fuel injector retaining clips Fuel injectors
To install:
Install or connect the following:
Fuel injectors. Use new O-ring seals. Fuel injector retaining clips Fuel supply manifold with injectors attached. Tighten the bolts to 60 inch lbs. (6.5 Nm). Fuel lines Fuel injector wiring connectors Engine cover Negative battery cable
Start the engine and check for leaks.
3.5L VIN Y Engine
Before servicing the vehicle, refer to the Precautions Section.
Relieve fuel system pressure.
Disconnect the battery ground.
Fig. Fuel rail and injectors-3.5L VIN Y engine
Remove the intake manifold.
Disconnect the fuel supply line.
Remove the joint pipe.
Remove the bolts and the fuel rail.
Remove the O-ring and back-up ring from the injectors.
Fig. Injector installed in head-3.5L VIN Y engine
Remove the spring clip and remove each injector with a slidehammer.
Fig. Injector removal-3.5L VIN Y engine
Use needle-nose pliers to pull and cut the TIP seal from each injector. Take care to avoid damage to the injector.
To install:
Install a new TIP seal with tool J46911:
Place the new seal on the tool.
Align the thick end of the tool with the injector nozzle.
Use the pusher to install the seal.
Fig. Install a new TIP seal-3.5L VIN Y engine
Pull the tool from the injector.
Use the resizing tool to twist and shape the seal to the proper taper.
Fig. Size the new seal-3.5L VIN Y engine
Clean and debris from the seal and apply clean engine oil.
Install new O-rings and back-up rings on the injectors.
Clean the injector bores thoroughly.
Install new spring clips and install the injectors.
The remainder of installation is the reverse of removal. Torque the fuel rail bolts to 18 ft. lbs. (25 Nm). Torque the fuel lines connections to 84 inch lbs. (10 Nm).
Fuel System Service Precautions
Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines.
To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. Always keep a dry chemical (Class B) fire extinguisher near the work area. Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always replace worn fuel fitting O-rings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.
Before servicing the vehicle, make sure to also refer to the precautions in the beginning of this section as well.
Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines.
To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. Always keep a dry chemical (Class B) fire extinguisher near the work area. Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always replace worn fuel fitting O-rings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.
Before servicing the vehicle, make sure to also refer to the precautions in the beginning of this section as well.
High Pressure Fuel Pump
REMOVAL & INSTALLATION
Removal & Installation
3.5L VIN Y Engine
The high pressure pump is located at the rear of the right cylinder head.
Before servicing the vehicle, refer to the Precautions Section.
Relieve fuel system pressure.
Disconnect the battery ground.
Fig. High pressure fuel pump-3.5L VIN Y engine
Remove the fuel filler cap.
Drain the coolant.
Remove the intake manifold.
Remove the fuel rail joint pipe.
Disconnect the fuel pressure sensor, injectors and knock sensor.
Disconnect the harness clip.
Remove the heater hoses.
Remove the high pressure pump cover plate.
Disconnect the fuel lines at the high pressure pump.
Remove the 2 bolts and the pump.
Installation is the reverse of removal. Torque the pump bolts to 18 ft. lbs. (25 Nm) and the fuel line connectors to 84 inch lbs. (10 Nm).
Throttle Body
REMOVAL & INSTALLATION
Removal & Installation
2.2L Engine
Disconnect the negative battery cable.
Drain the cooling system
Remove the air intake duct.
Remove the accelerator cable from throttle body.
Disconnect the electrical connectors from the throttle position sensor and the idle air control valve solenoid.
Disconnect all vacuum hoses below air horn.
Disconnect coolant lines.
Remove the mounting bolts retaining the throttle body the intake manifold.
Lift up the throttle body from the intake manifolds.
Remove the gaskets from the intake manifolds.
Remove the Idle Air Control (IAC) valve.
Remove the Throttle Position Sensor (TPS).
WARNING
Never use solvent of any type when you clean the gasket surfaces on the intake manifold and the throttle body assembly. The gasket surface and the throttle body assembly may be damaged as a result.
If the throttle body gasket needs to be released, remove any gasket material that may be stuck to the mating surfaces of the manifold. Do not leave any scratches in the aluminum casting.
To install:
Install the IAC valve onto the throttle body.
Install the TPS onto the throttle body if necessary.
Place the gasket then the throttle body on the manifold.
Install the four mounting bolts and tighten to . Tighten the throttle body ft. lbs. (13.5 Nm).
Connect the coolant line and secure them with clamps.
Connect all vacuum hoses and secure them with clamps if necessary.
Install the accelerator control cable bracket onto the throttle body.
Connect the accelerator control cable to throttle plate.
Attach the electrical connectors to the IAC valve and TPS.
Install the air intake duct.
Fill the cooling system with required coolant.
Connect the negative battery cable.
3.2L Engine
Disconnect the negative battery cable.
Drain the cooling system.
Disconnect the Throttle position (TP) sensor and Intake air temperature (IAT) sensor electrical connectors.
Fig. Disconnect the Throttle position (TP) sensor and Intake air temperature (IAT) sensor electrical connectors
Disconnect the vacuum hose below the air horn.
Remove the intake air duct clamp.
Disconnect the intake air duct.
Disconnect the coolant lines from the throttle body.
Remove the bolts from the common chamber.
Remove the throttle body from the common chamber.
Remove the gasket from the common chamber.
Remove the Throttle Position (TP) sensor.
WARNING
Never use solvent of any type when you clean the gasket surfaces on the intake manifold and the throttle body assembly. The gasket surfaces and the throttle body assembly may be damaged as a result.
If the throttle body gasket needs to be replaced, remove any gasket material that may be stuck to the mating surfaces of the manifold. Do not leave any scratches in the aluminum casting.
Fig. Throttle body mounting-3.2L engine
To install:
Install the TP sensor.
Install the gasket on the common chamber.
Install the throttle body on the common chamber.
Secure the gasket and the throttle body with the four bolts.
NOTE
The vacuum lines must be properly routed under the throttle body before tightening the mounting bolts.
Tighten the throttle body mounting bolts to 89 inch lbs. (10 Nm).
Install the coolant lines.
Connect all the vacuum lines.
Install the intake air duct.
Tighten the intake air duct clamp.
Connect all the electrical connectors:
Install the accelerator cable assembly.
Fill the cooling system.
Connect the negative battery cable.
3.5L Engine
Disconnect the negative battery cable.
Disconnect the Throttle position (TP) sensor electrical connector
Disconnect the vacuum hose below the air horn.
Remove the intake air duct clamp.
Disconnect the intake air duct.
Remove the bolts from the common chamber.
Remove the throttle body from the common chamber.
Remove the gasket from the common chamber.
WARNING
Never use solvent of any type when you clean the gasket surfaces on the intake manifold and the throttle body assembly. The gasket surfaces and the throttle body assembly may be damaged as a result.
If the throttle body gasket needs to be replaced, remove any gasket material that may be stuck to the mating surfaces of the manifold. Do not leave any scratches in the aluminum casting.
Fig. Throttle body mounting-3.5L engine
To install:
Install the gasket on the common chamber.
Install the throttle body on the common chamber.
Secure the gasket and the throttle body with the four HEX bolts. Tighten the throttle body mounting bolts to 7.4 ft. lbs. (10 Nm).
Connect all the vacuum lines.
Install the intake air duct.
Tighten the intake air duct clamp.
Connect all the electrical connectors:
Connect the negative battery cable.
Relieving Fuel System Pressure
Before servicing the vehicle, refer to the Precautions Section.
Remove the fuel filler cap.
Remove the fuel pump relay from the underhood relay box.
Start the engine and let it run until it stalls, then crank the engine for an additional 30 seconds.
Turn the ignition switch to the OFF position and remove the key. Disconnect the negative battery cable.
When service is completed, install the fuel pump relay and connect the negative battery cable.
