Fuel Supply Rail & Fuel Injectors

Removal & Installation

2.0L Engine

To Remove:

1. Relieve the fuel system pressure.
2. Remove the PCV hose.
3. Disconnect the connectors from the following;
   • EGR solenoid
   • manifold differential pressure sensor
   • purge control solenoid
   • throttle position sensor
   • idle air control motor
   • fuel injectors
4. Disconnect the fuel line from the fuel rail.
5. Remove the fuel rail mounting bolts and the fuel rail with injectors attached from the engine. Do not drop the fuel injectors.
6. Remove the fuel injectors from the fuel rail.

To Install:

1. Install the fuel injectors in the fuel rail with new O-rings. Lubricate the O-rings with engine oil. Do not get oil into the fuel rail.
2. Install the fuel rail and injectors.
3. Connect the high pressure fuel line to the fuel rail. Lubricate the new o-ring with engine oil. Do not get oil into the fuel rail.
4. Connect the electrical connectors to the following;
   • EGR solenoid
   • manifold differential pressure sensor
   • purge control solenoid
   • throttle position sensor
   • idle air control motor
   • fuel injectors
5. Install the PCV hose.
6. Pressurize the fuel system by turning the key to on and check for leaks.

2.0L Turbo Engine

To Remove:

1. Relieve the fuel system pressure.
2. Remove the strut tower brace.
3. Remove air hose E, the air bypass hose and air pipe C from the charge air cooler assembly.
4. Disconnect the fuel injector connectors and move the harness out of the way.
5. Disconnect the accelerator cable from the throttle body.
6. Disconnect the fuel supply and return lines from the fuel rail.
7. Remove the fuel rail mounting bolts and the fuel rail with injectors attached from the engine. Do not drop the fuel injectors.
8. Remove the fuel injectors from the fuel rail.

To Install:

1. Install the fuel injectors in the fuel rail with new O-rings. Lubricate the O-rings with engine oil. Do not get oil into the fuel rail.
2. Install the fuel rail and injectors.
3. Connect the high pressure and return fuel lines to the fuel rail.
4. Connect the accelerator cable to the throttle body.
5. Connect the fuel injector connectors and install the harness in the original location.
6. Install the charger air cooler components.
7. Install the strut tower brace.
8. Pressurize the fuel system by turning the key to on and check for leaks.

2.4L Engine

To Remove:

1. Relieve the fuel system pressure.
2. Disconnect the PCV hose.
3. Disconnect the connectors from the fuel injectors and ignition coils.
4. Disconnect the EGR valve, throttle position, MAP sensor, knock sensor, PSP switch and EVAP purge solenoid connectors.
5. Remove the rocker cover bracket bolts holding the wiring harness.
6. Disconnect the high pressure line from the fuel rail.
7. Remove the fuel rail mounting bolts.
8. Remove the fuel injectors from the fuel rail.

To Install:

1. Install the fuel injectors in the fuel rail with new O-rings. Lubricate the O-rings with engine oil.
2. Install the fuel rail and injectors.
3. Connect the high pressure line to the fuel rail.
4. Install the rocker cover bracket bolts holding the wiring harness.
5. Connect the EGR valve, throttle position sensor, MAP sensor, knock sensor, PSP switch and EVAP purge solenoid connectors.
6. Connect the connectors from the fuel injectors and ignition coils.
7. Connect the PCV hose.
8. Pressurize the fuel system by turning the key to on and check for leaks.