Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Fuel Injectors

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Removal & Installation



2.0L & 2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  6.  
  7. Remove or disconnect the following:
    NOTE
    Cover the fuel injector holes in the intake manifold.



    Fuel supply line quick-connect fitting from the fuel rail
     
    Fuel injector electrical connectors
     
    Fuel rail from the intake manifold
     



    Fuel injector clip
     
    Fuel injector(s) from the fuel rail and discard the O-rings
     

  8.  

To install:

  1. Install or connect the following:

    Fuel injector to the fuel rail using new O-rings lubricated with engine oil
     
    Fuel injector clip
     
    Fuel rail and torque the screws to 14-19 ft. lbs. (19.5-25.5 Nm)
     
    Fuel injector electrical connectors
     
    Fuel supply line quick-connect fitting to the fuel rail
     
    Negative battery cable
     

  2.  
  3. Use a scan tool and run Automatic Shutdown (ASD) fuel system test to pressurize the fuel system. Check for leaks.

    Click image to see an enlarged view

    Fig. View of the fuel injector-2.0L and 2.4L engines

  4.  

  1. Perform fuel system pressure release procedure before servicing or starting repairs.
  2.  
  3. Disconnect negative cable from battery.
  4.  
  5. Remove the wiring harness from fuel rail support bracket.
  6.  
  7. Remove the fuel rail support bracket.
  8.  
  9. Disconnect the wiring connectors for fuel injectors harness.
  10.  
  11. Remove the wiring harness from fuel rail brackets.
  12.  
  13. Disconnect the connectors from the fuel injectors.
  14.  
  15. Remove the throttle and speed control cables from the fuel rail.
  16.  
  17. Remove the fuel hose quick connect fitting from the chassis tube. Place a shop towel under the connections to absorb any fuel spilled from the fitting.
    CAUTION
    Wrap a shop towel around hoses to catch any gasoline spillage.

  18.  
  19. Remove the fuel rail attaching bolts.
  20.  
  21. Remove the fuel rail. Be careful not to damage the injector O-rings upon removal from their ports.
  22.  
  23. Position fuel rail assembly so that the fuel injectors are easily accessible.
  24.  
  25. Remove the injector clip and pull injector out of fuel rail.
  26.  
  27. Check injector O-ring for damage. If O-ring is damaged, it must be replaced. Replace the injector clip if it is damaged.
  28.  
  29. Repeat for remaining injectors.

    Click image to see an enlarged view

    Fig. Fuel rail and bracket-2.4L engine



    Click image to see an enlarged view

    Fig. Fuel injector and rail-2.4L engine

  30.  

To install:

  1. Before installing an injector the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation.
  2.  
  3. Install the injector clip by sliding open end into the top slot of the injector. The edge of the receiver cup will slide into the side slots of clip.
  4.  
  5. Install the injector top end into fuel rail receiver cap. Be careful not to damage O-ring during installation.
  6.  
  7. Repeat steps for remaining injectors.
  8.  
  9. Ensure injector holes are clean. Replace O-rings if damaged.
  10.  
  11. Lubricate injector O-rings with a drop of clean engine oil to ease installation.
  12.  
  13. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports.
  14.  
  15. Install the 2 fuel rail mounting bolts to intake manifold. Tighten bolts to 105 inch lbs. (12 Nm).
  16.  
  17. Install the fuel rail mounting bolt to cylinder head. Tighten bolt to 16 ft. lbs. (22 Nm)
  18.  
  19. Connect the connectors to the fuel injectors.
  20.  
  21. Install the fuel rail support bracket and loosely. Install the all bolts.
  22.  
  23. Tighten three fasteners to intake manifold to 21 ft. lbs. (28 Nm).
  24.  
  25. Tighten two bolts to fuel rail to 75 inch lbs. (8.5 Nm).
  26.  
  27. Install the wiring harness to brackets.
  28.  
  29. Connect the throttle and speed control cables to fuel rail bracket.
  30.  
  31. Connect negative battery cable.
  32.  
  33. Use a scan tool to pressurize the fuel system. Check for leaks.
  34.  

2.5L & 2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  6.  
  7. Remove or disconnect the following:
    NOTE
    Cover the intake manifold openings to keep dirt from entering the system.



    Fuel supply line quick-connect fitting from the fuel rail
     
    Upper intake manifold plenum and discard the gasket
     
    Fuel injector electrical connectors
     
    Fuel rail from the intake manifold
     



    Fuel injector clip
     
    Fuel injector(s) from the fuel rail and discard the O-rings

    Click image to see an enlarged view

    Fig. View of the fuel rail assembly-2.5L and 2.7L engines

     

  8.  

To install:

  1. Install or connect the following:
    NOTE
    Be sure the spacers are located under the fuel rail



    Fuel injector to the fuel rail using new O-rings lubricated with engine oil
     
    Fuel injector clip
     
    Fuel rail and torque the bolts to 8 ft. lbs. (12 Nm)
     



    Fuel injector electrical connectors
     
    Fuel supply line quick-connect fitting to the fuel rail
     
    Upper intake manifold plenum using a new gasket and torque the bolts to 13 ft. lbs. (18 Nm)
     
    Throttle cables
     
    Sensor electrical connectors
     
    Negative battery cable
     

  2.  
  3. Use a scan tool and run Automatic Shutdown (ASD) fuel system test to pressurize the fuel system. Check for leaks.
  4.  

Testing





Click image to see an enlarged view

Fig. Fuel injector diagnosis

 
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