Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Fuel Rail, Fuel Pressure Regulator and Injectors

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REMOVAL & INSTALLATION



See Figures 1 through 7

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Fig. Fig. 1: The fuel rail and related components used with 2.2L Turbo I and Turbo II engines



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Fig. Fig. 2: The fuel rail and related components used with the newer MFI engines-2.2L Turbo III, 2.5L Turbo I and 2.5L Flex Fuel engines



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Fig. Fig. 3: Once the fuel rail and fuel injectors are removed, clean the injector bores of all dirt and grime



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Fig. Fig. 4: The fuel injector wiring harness connector is secured to the injector with a lockring-the lockring must be removed before the injector and wiring connector can be separated



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Fig. Fig. 5: Apply a drop of engine oil to the new O-ring on the injector inlet end, then gently install it to the fuel rail



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Fig. Fig. 6: The fuel pressure regulator is mounted onto the fuel rail with 2 attaching nuts



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Fig. Fig. 7: When the pressure regulator is removed for any reason, the O-ring sealing it to the fuel rail must be replaced with a new one


CAUTION
Before servicing any component of the Flex Fuel system make certain to read the warnings and cautions provided in Routine Maintenance . This is very important since the methanol fuel used in this system can cause severe physical injury.

A set of four injector nozzle protective caps and a set of new O-rings should be purchased prior to removing the fuel injectors.

  1. Release fuel system pressure as described earlier in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. On earlier models, loosen the hose clamp on the fuel supply hose at the fuel rail inlet and disconnect it; on newer models, unfasten the quick-connect fitting and disconnect the fuel supply hose. Collect any fuel that may drain out into a metal cup and dispose of it safely.
  6.  
  7. Disconnect the fuel pressure regulator vacuum hose, if equipped, from the intake manifold vacuum tree.
  8.  
  9. Remove the 2 fuel pressure regulator-to-intake manifold bracket screws.
  10.  
  11. Loosen the clamp, or unfasten the quick-connect fitting (whichever applies), at the rail end of the fuel rail-to-pressure regulator hose, then remove the regulator and hose. Collect any fuel that may drain out into a metal cup and dispose of it safely.
  12.  
  13. Remove the fuel rail-to-rocker arm cover bracket bolt.
  14.  
  15. Remove the fuel injector head shield clips, then remove the four intake manifold-to-rail mounting bolts. Note that one bolt retains an engine ground strap.
  16.  
  17. Pull the rail away from the manifold in such a way as to pull the injectors straight out of their mounting holes. They should be pulled out straight so as to avoid damaging their O-rings.
  18.  
  19. To remove individual injectors from the rail, first position the rail on a bench or other clean, flat surface so that the injectors are easily attached. Perform the following for each injector to be removed:
    1. Disengage the wiring connector.
    2.  
    3. Remove the lockring from the fuel rail and injector.
    4.  
    5. Pull the injector straight out of the injector receiver cup in the fuel rail.
    6.  
    7. Inspect the injector O-rings for damage. Replace the O-ring if necessary. If the injector will be re-used and will remain off the rail while other work is performed, install a protective cap over the nozzle.
    8.  
    9. Lubricate the O-ring that seals the upper end of the fuel injector with a drop of clean engine oil. Then, install the inlet end carefully into the fuel rail receiver cup. Proceed slowly and insert the injector straight in to avoid damaging the O-ring.
    10.  
    11. Slide the open end of the injector lockring down over the injector and onto the ridge in the receiver cup. The lockring must lock into the slot on the top of the injector.
    12.  

  20.  

To install:
  1. Remove all protective covers installed over the injector tips. Make sure the bores of the injector mounting holes are clean.
  2.  
  3. Put a drop of clean engine oil on the O-ring at the nozzle end of each injector. Then position the rail with the injectors positioned squarely in their mounting holes, then gently, and evenly, slide all four injectors into place.
  4.  
  5. Install the four rail mounting bolts and tighten them to 21 ft. lbs. (28 Nm). Make sure to reconnect the ground strap removed earlier.
  6.  
  7. Connect each wiring harness plug to its corresponding injector. Install each wiring harness into its clips. Connect the injector wiring harness to the main harness.
  8.  
  9. Install the heat shield clips. Install the bolt fastening the rail mounting bracket to the rocker arm cover.
  10.  
  11. Connect the vacuum line for the fuel pressure regulator to the vacuum tree on the manifold, then connect the fuel return hose to the fuel pressure regulator (on models not equipped with quick-connect fittings, use a wrench to hold the fuel pressure regulator while tightening the fuel tube nut), then position and tighten the clamp. On newer models, make sure that the quick-connect fitting is properly engaged. Install the bolts fastening the regulator bracket to the intake manifold.
  12.  
  13. Attach the fuel supply hose to the fuel rail and, if applicable, position and tighten the clamp.
  14.  
  15. Recheck all wiring and hose connections for routing and tightness.
  16.  
  17. Connect the negative battery cable, start the engine, and check for fuel leaks.
  18.  

 
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