Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Fuel Rail (Supply Manifold) & Injectors

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NOTE
Before servicing the vehicle, also refer to the precautions in the beginning of this section.

Removal & Installation



2.0L & 2.4L Engines
  1. Relieve fuel system pressure.
  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.

    Click image to see an enlarged view

    Fig. Fuel injector harness connectors-2.0L and 2.4L engines

  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.
  18.  
  19. Place a shop towel under the connections to absorb any fuel spilled from the fitting.
  20.  
  21. Remove the fuel rail attaching bolts.
  22.  
  23. Remove the fuel rail. Be careful not to damage the injector O-rings upon removal from their ports.
  24.  

To install:

  1. Make sure injector holes are clean. Replace O-rings if damaged.
  2.  
  3. Lubricate injector O-rings with a drop of clean engine oil to ease installation.
  4.  
  5. Install the injectors into cups of fuel rail and check to ensure retaining clips are securely attached.
  6.  
  7. Install the 2 fuel rail mounting bolts to intake manifold.
    1. Tighten bolts to 105 inch lbs. (11.9 Nm).
    2.  

  8.  
  9. Install the fuel rail mounting bolt to cylinder head.
    1. Tighten bolt to 16 ft. lbs. (22 Nm)
    2.  

  10.  
  11. Connect the connectors to the fuel injectors.
  12.  
  13. Install the fuel rail support bracket and loosely Install the all bolts.
    1. Tighten three fasteners to intake manifold to 21 ft. lbs. (28.3 Nm).
    2.  
    3. Tighten two bolts to fuel rail to 75 inch lbs. (8.5 Nm)
    4.  

  14.  
  15. Install the wiring harness to brackets.
  16.  
  17. Connect the throttle and speed control cables to fuel rail bracket.
  18.  
  19. Connect negative battery cable.
  20.  
  21. Use a scan tool to pressurize the fuel system. Check for leaks.
  22.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable and properly isolate to prevent accidental reconnection.
     
    Air intake hose
     
    High pressure fuel hose connection and discard O-ring
     
    Fuel injector harness connector
     
    Fuel injector electrical connectors
     
    Fuel rail and injectors as an assembly
     
    Fuel injector-to-fuel rail retaining clips
     
    Fuel injectors and discard the O-rings

    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector, fuel rail and related components-2.0L engine

     

  6.  

To install:

  1. Lubricate the O-rings with clean engine oil; then, install the injectors into the fuel rail by twisting them (left and right) to make sure that they turn smoothly in the seat.
    WARNING
    Do not allow engine oil to get into the fuel rail.

  2.  
  3. Install or connect the following:
    WARNING
    Do not allow engine oil to get into the fuel hose.



    Fuel injector-to-fuel rail retaining clips
     
    Fuel injector electrical connectors
     
    Fuel rail
     
    Fuel injector harness connector
     
    New high-pressure fuel hose O-ring lubricated with clean engine oil
     



    High pressure fuel hose connection and torque the fuel hose-to-fuel rail bolts to 1.8 ft. lbs. (2.5 Nm)
     
    Air intake hose
     
    Battery
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable and properly isolate to prevent accidental reconnection.
     
    Power steering oil pressure switch connector
     
    Heated Oxygen (HO 2 ) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Injector connectors
     
    Control wiring harness
     
    Intake manifold plenum
     
    Fuel injector electrical connectors
     
    High pressure fuel hose connection
     
    O-ring from the high pressure fuel hose connection
     
    Fuel rail and injectors as an assembly
     
    Fuel injector retaining clips
     
    Fuel injector(s) and discard the O-rings and grommet

    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector, fuel rail and related components-2.5L engine

     

  6.  

To install:

  1. Lubricate the O-rings and grommet(s) with clean engine oil; then install the injectors into the fuel rail by twisting them (left and right) to make sure that they turn smoothly in the seat.
    WARNING
    Do not allow engine oil to get into the fuel rail.

  2.  
  3. Install or connect the following:

    New fuel injector O-rings and grommet(s)
     
    Fuel injectors
     
    Fuel injector-to-fuel rail retaining clips
     
    Fuel injector electrical connectors
     
    Fuel rail and torque the fuel rail-to-intake manifold bolts to 7.2-9.4 ft. lbs. (10-13 Nm)
     
    New high-pressure fuel hose O-ring
     

  4.  
  5. Lubricate the O-ring with clean engine oil.
    WARNING
    Do not allow engine oil to get into the fuel rail.



    High pressure fuel hose connection and torque the fuel hose-to-fuel rail bolts to 1.8 ft. lbs. (2.5 Nm)
     
    Intake manifold plenum
     
    Control wiring harness
     
    Injector connectors
     
    IAT sensor connector
     
    HO 2 S sensor connector
     
    Power steering oil pressure switch connector
     

  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

  1. Relieve fuel system pressure.
  2.  
  3. Disconnect negative cable from auxiliary jumper terminal.
    NOTE
    Wrap shop towels around hose to catch any gasoline spillage.

  4.  
  5. Disconnect fuel supply tube from rail.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Disconnect the electrical connectors from fuel injectors.
  10.  
  11. Remove the 4 bolts holding fuel rail.
  12.  
  13. Lift fuel rail off engine.
  14.  
  15. There are spacers under each fuel rail bolt.

    Click image to see an enlarged view

    Fig. Fuel rail bolts (1)-2.5L engine

  16.  

To install:

  1. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector
    NOTE
    Make sure spacers are located under each fuel rail mounting position.

  2.  
  3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
    1. Tighten fuel rail bolts to 105 inch lbs. (12 Nm)
    2.  

  4.  
  5. Attach electrical connectors to fuel injectors.
  6.  
  7. Connect fuel supply tube to fuel rail.
  8.  
  9. Install the Intake Manifold.
  10.  
  11. Install the throttle cables.
  12.  
  13. Attach electrical connectors to sensors.
  14.  
  15. Tighten air inlet tube clamps to 25 inch lbs. (3 Nm)
  16.  
  17. Connect negative terminal to auxiliary jumper terminal.
  18.  

2.7L Engine
  1. Relieve fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the intake manifold plenum.
  6.  
  7. Remove the intake manifold plenum mounting bolts. Lift Plenum up off of engine.
  8.  
  9. Cover intake manifold to prevent foreign material from entering engine.
  10.  
  11. Disconnect fuel supply tube quick connect fitting at the rear of the fuel rail.
  12.  
  13. If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder.
  14.  
  15. Remove the electrical connectors from the fuel injectors.
  16.  
  17. Remove the mounting bolts on both sides of fuel rail.
  18.  
  19. Lift fuel rail straight up off of cylinder head.
  20.  
  21. Remove the retaining clips from fuel injectors at fuel rail.
  22.  
  23. Remove the fuel injector from fuel rail.
  24.  

To install:

Click image to see an enlarged view

Fig. Fuel injector harness connectors-2.7L engine

  1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
  2.  
  3. Install the 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.
    1. Tighten fuel rail mounting bolts to 105 inch lbs. (11.9 Nm)
    2.  

  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 the intake manifold plenum.
  14.  
  15. Connect negative cable to battery.
  16.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable and properly isolate to prevent accidental reconnection.
     
    Intake manifold plenum
     
    Fuel injector electrical connector
     
    Fuel supply and return hoses
     
    Vacuum hose
     
    Fuel pressure regulator
     
    Fuel rail with the injectors
     
    Insulators
     
    Fuel injectors and discard the O-rings

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail, injectors and related components-3.0L engine

     

  8.  

To install:

  1. Use a drop of engine oil on the new O-rings and install the injector into the fuel rail using a left-right twisting motion.
  2.  
  3. After it is installed, make sure the injector turns freely. If it does not, the O-ring may be pinched.
    WARNING
    Do not get engine oil into the fuel rail.

  4.  
  5. Install or connect the following:

    Insulators
     
    Fuel rail and torque the bolts to 100 inch lbs. (12 Nm)
     
    Fuel pressure regulator and torque the bolts to 78 inch lbs. (9 Nm)
     
    Vacuum hose
     
    Fuel return and supply hoses
     
    Fuel injector electrical connector
     
    Intake manifold plenum
     
    Negative battery cable
     

  6.  
  7. Fill the engine with coolant, start the vehicle, check for leaks and repair if necessary.
  8.  

 
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