Dodge Omni/Horizon/Rampage 1978-1989 Repair Guide

Fuel Rail and Injectors

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REMOVAL & INSTALLATION




WARNING
You should have a set of four injector nozzle protective caps and a set of new O-rings before removing the injectors.

  1. Release fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Loosen the hose clamp on the fuel supply hose at the fuel rail inlet and disconnect it. Collect any fuel that may drain out into a metal cup and dispose of it safely.
  4.  
  5. Disconnect the fuel pressure regulator vacuum hose at the intake manifold vacuum tree.
  6.  
  7. Remove the 2 fuel pressure regulator-to-intake manifold bracket screws.
  8.  



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Fig. Fig. 1 Fuel rail components



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Fig. Fig. 2 Always replace the O-rings with new ones

  1. Loosen the clamp at the rail end of the fuel rail-to-pressure regulator hose and then remove the regulator and hose. Collect any fuel that may drain out into a metal cup and dispose of it safely.
  2.  
  3. Remove the bolt from the fuel rail-to-valve cover bracket.
  4.  
  5. Remove the fuel injector head shield clips. Then, remove the four intake manifold-to-rail mounting bolts. Note that one bolt retains a ground strap.
  6.  
  7. Pull the rail away from the manifold in such a way as to pull the injectors straight out of their mounting holes. Pull the injectors out straight so as to avoid damaging their O-rings.
  8.  
  9. To remove individual injectors from the rail, first position the rail on a bench or other surfaces so that the injectors are easily reached. Perform the following for each injector to be removed:
  10.  
    1. Disconnect the wiring.
    2.  
    3. Remove the lockring from the 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 it if necessary. If the injector will be re-used and will be 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 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.  


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 headed squarely into their mounting holes and gently and evenly slide all four injectors into place.
  4.  
  5. Install the four rail mounting bolts and tighten them to 250 inch lbs. (28 Nm). Make sure to reconnect the ground strap removed earlier.
  6.  
  7. Connect each 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 valve 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 and position and tighten the clamp. Install the bolts fastening the regulator bracket to the intake manifold.
  12.  
  13. Attach the fuel supply hose to the fuel rail and position and tighten the clamp.
  14.  
  15. Recheck all wiring and hose connections for routing and tightness. Then, connect the battery, start the engine, and check for leaks.
  16.  

 
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