ION, L-Series, S-Series 1999-2005

Fuel Rail (Supply Manifold) & Injectors

Print

Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the coolant overflow pipe.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Use a back up wrench on the fuel rail and disconnect the fuel supply pipe.
  10.  
  11. Remove the fuel rail attaching studs.
    NOTE
    Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips.

  12.  
  13. Remove the fuel rail using the following procedure:
    1. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
    2.  
    3. Rotate the fuel rail in order to position the injectors downward.
    4.  
    5. Remove the fuel rail.
    6.  

  14.  
  15. Disconnect the fuel injector harness connectors.
  16.  
  17. Remove the fuel injector retainer clip.
  18.  
  19. Remove the fuel injectors from the fuel rail.
  20.  
  21. Visually inspect the fuel injector in order to determine if the upper O-ring was also removed. If the upper O-ring is not removed, remove the O-ring from the fuel rail assembly.
  22.  
  23. Remove and discard the fuel injector O-rings.
  24.  

To install:


NOTE
Always install new injector O-rings when servicing the fuel injectors. Lubricate the new injector O-rings with clean engine oil

  1. Install the O-rings on the fuel injector.
  2.  
  3. Install the fuel injector clip on the fuel injector.
    NOTE
    The fuel injector will click when the injector is installed correctly.

  4.  
  5. Install the fuel injector in the fuel rail with the connector facing upward.
  6.  
  7. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
    NOTE
    Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings with clean engine oil prior to installing the injectors into the intake manifold.

  8.  
  9. Install the fuel rail using the following procedure:
    1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
    2.  
    3. Align the injectors by rotating the fuel rail forward.
    4.  
    5. Carefully push the fuel injectors into the cylinder head ports.
    6.  
    7. Install the fuel rail attaching studs. Tighten the fuel rail studs to 89 inch lbs. (10 Nm).
    8.  

  10.  
  11. Install the fuel supply pipe.
  12.  
  13. Using a backup wrench on the fuel rail tighten the fuel supply pipe to 10 ft .lbs. (14 Nm).
  14.  
  15. Install the coolant overflow pipe. Tighten the pipe bolt to 71 inch lbs. (8 Nm).
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  20.  

2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake tube
     
    Fuel pressure regulator hose
     
    Fuel feed line
     
    Throttle body
     
    Throttle control cable bracket
     
    Fuel injector electrical connectors
     
    Fuel rail
     
    Fuel injector retaining clip off the injector
     
    Fuel injector
     
    Fuel injector O-rings

    Click image to see an enlarged view

    Fig. Remove the retainer clip from the fuel injector-2.2L

     

  6.  

To install:

  1. Lubricate the new fuel injector O-ring with clean engine oil.
  2.  
  3. Install or connect the following:

    New O-ring seals on the fuel injector
     
    Retaining clip to the fuel injector
     
    Fuel injector to the fuel rail
     
    Fuel rail and torque the bolts to 89 inch lbs. (10 Nm)
     
    Fuel injector electrical connectors
     
    Throttle control cable bracket
     
    Throttle body and torque the bolts to 89 inch lbs. (10 Nm)
     
    Fuel feed line
     
    Fuel pressure regulator hose
     
    Air intake tube
     
    Negative battery cable
     

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

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Disconnect the fuel feed line quick connect fitting from the fuel rail.
  8.  
  9. Cap or plug the fuel line and the fuel rail to prevent contamination.
  10.  
  11. Disconnect the engine harness electrical connector from the fuel injector harness.
  12.  
  13. Remove the fuel injector harness connector clip from the intake manifold.
  14.  
  15. Disconnect the engine harness electrical connector from the Manifold Absolute Pressure (MAP) sensor.
  16.  
  17. Remove the fuel rail bolts.
    NOTE
    Use care when removing the fuel rail assembly in order to prevent damage to the fuel injector electrical connector terminals and spray tips.

  18.  
  19. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
  20.  
  21. Remove the fuel rail.
  22.  
  23. Remove the fuel injectors.
  24.  

To install:


NOTE
Install NEW lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.

  1. Install the fuel injectors.
  2.  
  3. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  4.  
  5. Carefully push the fuel injectors into the cylinder head ports.
  6.  
  7. Install the fuel rail bolts and tighten the bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the engine harness electrical connector to the MAP sensor.
  10.  
  11. Connect the engine harness electrical connector to the fuel injector harness.
  12.  
  13. Install the fuel injector harness connector clip to the intake manifold.
  14.  
  15. Remove the caps or plugs from the fuel line and the fuel rail.
  16.  
  17. Connect the fuel feed line quick connect fitting to the fuel rail.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Start the vehicle and check for leaks, repair if necessary.
  22.  
  23. Install the air cleaner outlet duct.
  24.  

 
label.common.footer.alt.autozoneLogo