300M, Concorde, Intrepid, LHS, 1998-2004

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.7L Engine

CAUTION
Release fuel system pressure before servicing fuel rail. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle.

Release fuel system pressure. Refer to Fuel System Pressure Release Procedure in this section.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove intake manifold plenum.
  4.  
  5. Cover intake manifold to prevent foreign material from entering engine.
  6.  
  7. Disconnect fuel supply tube quick connect fitting at the rear of the fuel rail.
  8.  
  9. Disconnect electrical connectors at fuel injectors. Refer to graphic.
  10.  
  11. Push red colored slider away from injector.
  12.  
  13. While pushing slider, depress tab and remove connector from injector.
    NOTE
    The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.

  14.  
  15. Remove mounting bolts on both sides of fuel rail.
  16.  
  17. Lift fuel rail straight up off of cylinder head.
  18.  
  19. Remove retaining clips from fuel injectors at fuel rail.
  20.  
  21. Remove fuel injector from fuel rail.
  22.  

To install:

  1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
  2.  
  3. Install retaining clips on fuel injectors.
  4.  
  5. Push injectors into fuel injector rail until clips are in the correct position.
  6.  
  7. Position fuel rail over cylinder heads, and push rail into place. Tighten fuel rail mounting bolts to 100 inch lbs. (11 Nm).
  8.  
  9. Connect the fuel supply tube quick connect fitting to the fuel rail.
  10.  
  11. Connect the electrical connectors to the fuel injectors.
  12.  
  13. Install intake manifold plenum.
  14.  
  15. Connect negative cable to battery.
  16.  
  17. Use the scan tool to pressurize the fuel system.
  18.  
  19. Check for leaks.
  20.  

3.2L & 3.5L Engines

CAUTION
Release fuel system pressure before servicing fuel rail. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle.

  1. Release fuel system pressure. Refer to Fuel System Pressure Release Procedure in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove intake manifold plenum.
  6.  
  7. Cover intake manifold to prevent foreign material from entering engine.
  8.  
  9. Disconnect fuel supply tube quick connect fitting at the rear of the fuel rail
  10.  
  11. Disconnect electrical connectors at fuel injectors. Refer to graphic.
  12.  
  13. Push red colored slider away from injector .
  14.  
  15. While pushing slider, depress tab and remove connector from injector.
    NOTE
    The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.

  16.  
  17. Remove mounting bolts on both sides of fuel rail.
  18.  
  19. Lift fuel rail straight up off of cylinder head.
  20.  
  21. Remove retaining clips from fuel injectors at fuel rail.
  22.  
  23. Remove fuel injector from fuel rail.
  24.  

To install:

  1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
  2.  
  3. Install retaining clips on fuel injectors.
  4.  
  5. Push injectors into fuel injector rail until clips are in the correct position.
  6.  
  7. Position fuel rail over cylinder heads, and push rail into place. Tighten fuel rail mounting bolts to 21 ft. lbs. (28 Nm).
  8.  
  9. Connect the fuel supply tube quick connect fitting to the fuel rail.
  10.  
  11. Connect the electrical connectors to the fuel injectors.
  12.  
  13. Install intake manifold plenum.
  14.  
  15. Connect negative cable to battery.
  16.  
  17. Use the scan tool to pressurize the fuel system.
  18.  
  19. Check for leaks.
  20.  

 
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