Avenger 2008

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.4L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


WARNING
Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.


NOTE
Wrap shop towels around hose to catch any gasoline spillage.

  1. Release the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the fuel line from the fuel rail.

    Click image to see an enlarged view

    Fig. Disconnect the fuel line from the fuel rail

  6.  
  7. Fuel line removed from the fuel rail.

    Click image to see an enlarged view

    Fig. Fuel line removed from the fuel rail

  8.  
  9. Unlock and disconnect the electrical connectors from the fuel injectors.

    Click image to see an enlarged view

    Fig. Unlock and disconnect the electrical connectors from the fuel injectors

  10.  
  11. Remove the wiring harness from the fuel rail studs.

    Click image to see an enlarged view

    Fig. Remove the wiring harness from the fuel rail studs

  12.  
  13. Remove the 2 bolts from the fuel rail.
  14.  
  15. Remove the fuel rail and injectors from the intake manifold.

    Click image to see an enlarged view

    Fig. Remove the fuel rail and injectors from the intake manifold

  16.  
  17. Remove fuel injectors from fuel rail.

    Click image to see an enlarged view

    Fig. Remove fuel injectors from fuel rail

  18.  

To install:

  1. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
  2.  
  3. Install the fuel injectors to the fuel rail.
  4.  
  5. Install injector into cup of fuel rail.
  6.  
  7. Install retaining clip and check to ensure injector is properly captured.
  8.  
  9. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
  10.  
  11. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 20 ft. lbs. (27 Nm).
  12.  
  13. Install the wiring harness to the fuel rail.
  14.  
  15. Connect and lock the electrical connectors to the fuel injectors.
  16.  
  17. Connect the fuel line to the fuel rail. Refer to Quick Connect Fittings in this group.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Use the Scan Tool Fuel System Test to pressurize the fuel system. Check for leaks.
  22.  

2.7L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


WARNING
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.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove intake manifold.
  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. If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder.
  12.  
  13. Remove electrical connectors from the fuel injectors.
  14.  
  15. Remove mounting bolts on both sides of fuel rail.
  16.  
  17. Lift fuel rail straight up off of cylinder head.

    Click image to see an enlarged view

    Fig. 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.

    Click image to see an enlarged view

    Fig. 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 105 inch lbs. (11.9 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.
  14.  
  15. Connect negative cable to battery.
  16.  

3.5L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


WARNING
The fuel system is under a constant pressure (even with the engine off). Before servicing any part on the fuel system, the fuel system pressure must be released.

  1. Release fuel pressure.
  2.  
  3. Disconnect and isolate negative battery cable at battery.
  4.  
  5. Remove the upper intake manifold.

    Click image to see an enlarged view

    Fig. Remove the upper intake manifold

  6.  
  7. Disconnect the quick connect fuel line from the fuel rail.
    NOTE
    Mark fuel injector electrical harness connectors with correct corresponding cylinder numbers.



    Click image to see an enlarged view

    Fig. Disconnect the quick connect fuel line from the fuel rail

  8.  
  9. Disconnect all fuel injector electrical connectors (1) from fuel injectors (2).

    Click image to see an enlarged view

    Fig. Disconnect all fuel injector electrical connectors (1) from fuel injectors (2)

  10.  
  11. Remove fuel rail mounting bolts from fuel rail and lower intake manifold.
    NOTE
    Gently rock the fuel rail and injectors back and forth to loosen the seals on the fuel injectors from the cylinder heads.


    CAUTION
    Do Not use excessive force or prying tools to remove fuel rail and injectors. Damage to the fuel rail and injectors may result.



    Click image to see an enlarged view

    Fig. Remove fuel rail mounting bolts from fuel rail and lower intake manifold

  12.  
  13. Lift fuel rail straight up off of the cylinder heads.
  14.  
  15. Drain any excess fuel from the fuel rail into an approved fuel storage container.
    NOTE
    Mark or tag each fuel injector with correct corresponding cylinder numbers.

  16.  
  17. Remove retaining clips (5) from fuel injectors (2) at fuel rail (4).

    Click image to see an enlarged view

    Fig. Remove retaining clips (5) from fuel injectors (2) at fuel rail (4)

  18.  

To install:


NOTE
Inspect each O-ring seal on all the fuel injectors, replace O-ring seals if any damaged is noted. Note the fuel injector O-rings are color coded. The Blue colored O-ring is for the fuel rail side and the Green colored O-ring is cylinder head side.

  1. Install and lubricate each fuel injector O-rings (1, 3) with a light drop of clean engine oil.

    Click image to see an enlarged view

    Fig. Install and lubricate each fuel injector O-rings (1, 3) with a light drop of clean engine oil

  2.  
  3. Install all of the fuel injectors (2) to the fuel rail (4), then install the retaining clips (5) to the fuel rail (4).
  4.  
  5. Inspect each fuel injector for proper installation. Note how the retaining clip (3) secures the fuel injector (1) to the fuel rail (2).
    CAUTION
    The fuel rail bolts are actually lower intake manifold bolts. These bolts must be torqued in a mandatory torque sequence.



    Click image to see an enlarged view

    Fig. Note how the retaining clip (3) secures the fuel injector (1) to the fuel rail (2)

  6.  
  7. Insert fuel injector nozzles into openings in the cylinder heads. Seat the injectors in place. Install the fuel rail bolts and tighten bolts in a mandatory torque sequence to 20.5 ft. lbs. (28 Nm).

    Click image to see an enlarged view

    Fig. Install the fuel rail bolts and tighten bolts in a mandatory torque sequence

  8.  
  9. Correctly position and connect all fuel injector electrical connectors to fuel injectors.
    CAUTION
    Make sure the fuel line quick connector is connected properly. Failure to connect the fuel line correctly may result in a fuel leak at the rail assembly. Fuel leaked onto a hot engine may ignite resulting in damage to the vehicle.

  10.  
  11. Connect quick connect fuel line to fuel rail.
  12.  
  13. Install upper intake manifold.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Use the scan tool ASD Fuel System Test to pressurize the fuel system.
  18.  
  19. Check for leaks.
  20.  

 
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