Mitsubishi Car 1999-05

Multi-Port Fuel Injection System (MFI) 2

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Fuel Rail (Supply Manifold) & Injectors



Removal & Installation
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    Work MUST NOT be started until at least 90 seconds after the ignition switch is turned to the LOCK position and the negative battery cable is disconnected from the battery. This will allow time for the air bag system backup power supply to deplete its stored energy preventing accidental air bag deployment which could result in unnecessary air bag system repairs and/or personal injury.

  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect all components from the air intake plenum and remove the plenum from the intake manifold.
  8.  
  9. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  10.  
  11. Remove or disconnect the following:

    Fuel return hose and remove the O-ring
     
    Vacuum hose from the fuel pressure regulator
     
    Electrical connectors from each injector
     
    Fuel pipe connecting the fuel rails
     
    Injector rail retaining bolts. Make sure the rubber mounting bushings do not get lost.
     

  12.  
  13. Lift the rail assemblies up and away from the engine.
  14.  
  15. Remove the injectors from the rail by pulling gently. Discard the lower insulator.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel injectors and related components-3.5L engine

  16.  

To install:


NOTE
Some of the vehicles may have a clip that secures the injector to the fuel rail. Be sure to remove or install the injector clip where necessary.

  1. Install or connect the following:

    New grommet and O-ring to the injector. Coat the O-ring with light oil.
     
    Injector to the fuel rail
     

  2.  
  3. Replace the seats in the intake manifold. Install the fuel rails and injectors to the manifold. Make sure the rubber bushings are in place before tightening the mounting bolts.
  4.  
  5. Tighten the retaining bolts to 84-108 inch lbs. (10-13 Nm). Install the fuel pipe with new gasket.
  6.  
  7. Install or connect the following:

    Electrical connectors to the injectors
     
    Fuel return hose
     
    O-ring, lightly lubricate it and connect the high pressure fuel line
     
    Intake plenum and all related items, using new gaskets
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Connect the negative battery cable and check the entire system for proper operation and leaks.
  12.  

1.5L And 1.8L Engines


Click image to see an enlarged view

Fig. Exploded view of the fuel injectors and related components-1.5L engine



Click image to see an enlarged view

Fig. Exploded view of the fuel injectors and related components-1.8L engine

  1. Relieve the fuel system pressure as described in this section.
  2.  
  3. Remove or disconnect the following:
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.



    Positive Crankcase Ventilation (PCV) hose from the valve cover
     
    Breather hose at the opposite end of the valve cover
     
    High pressure fuel line
     

  4.  
  5. Remove or disconnect the following:

    Vacuum hose from the fuel pressure regulator
     
    Fuel return hose from the pressure regulator
     
    Electrical connector from each injector. Label for reference
     
    Bolt(s) holding the fuel rail to the manifold. Carefully lift the rail up and remove it with the injectors attached. Take great care not to drop an injector. Place the rail and injectors in a safe location on the workbench; protect the tips of the injectors from dirt and/or impact.
     
    Injector insulators from the intake manifold, discard. The insulators are not reusable.
     
    Injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet and O-ring come off with the injector.
     

  6.  

To install:

  1. Install a new insulator in each injector port in the manifold.
  2.  
  3. Remove the old grommet and O-ring from each injector. Install a new grommet and O-ring; coat the O-ring lightly with clean, thin oil.
  4.  
  5. If the fuel pressure regulator was removed, replace the O-ring with a new one and coat it lightly with clean, thin oil. Insert the regulator straight into the rail, then check that it can be rotated freely. If it does not rotate smoothly, remove it and inspect the O-ring for deformation or jamming. When properly installed, align the mounting holes and tighten the retaining bolts to 84 inch lbs. (9 Nm). This procedure must be followed even if the fuel rail was not removed.
  6.  
  7. Install or connect the following:

    Injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage.
     
    Delivery pipe and injectors to the engine. Make certain that each injector fits correctly into its port and that the rubber insulators for the fuel rail mounts are in position.
     
    Fuel rail retaining bolts and tighten them to 108 inch lbs. (12 Nm)
     
    Wiring harnesses to the appropriate injector
     
    Fuel return hose to the pressure regulator, then connect the vacuum hose
     

  8.  
  9. Replace the O-ring on the high pressure fuel line, coat the O-ring lightly with clean, thin oil and install the line to the fuel rail. Tighten the mounting bolts.

    PCV hose and the breather hose
     
    Negative battery cable
     

  10.  
  11. Pressurize the fuel system and inspect all connections for leaks.
  12.  

1.5L, 1.8L And 2.0L SOHC Engines


Click image to see an enlarged view

Fig. Exploded view of the fuel injectors and related components-1.5L engine



Click image to see an enlarged view

Fig. Exploded view of the fuel injectors and related components-1.8L engine



Click image to see an enlarged view

Fig. Exploded view of the fuel injectors and related components-2.0L SOHC engine

  1. Relieve the fuel system pressure as described in this section.
  2.  
  3. Disconnect the PCV hose from the valve cover. Also disconnect the breather hose at the opposite end of the valve cover.
  4.  
  5. Remove the bolts holding the high pressure fuel line to the fuel rail and disconnect the line. Be prepared to contain fuel spillage; plug the line to keep out dirt and debris.
  6.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Remove the vacuum hose from the fuel pressure regulator.
  2.  
  3. Disconnect the fuel return hose from the pressure regulator.
  4.  
  5. Label and detach the electrical connectors from each injector.
  6.  
  7. Remove the bolt(s) holding the fuel rail to the manifold. Carefully lift the rail up and remove it with the injectors attached. Take great care not to drop an injector. Place the rail and injectors in a safe location on the workbench; protect the tips of the injectors from dirt and/or impact.
  8.  
  9. Remove and discard the injector insulators from the intake manifold. The insulators are not reusable.
  10.  
  11. Remove the injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet and O-ring come off with the injector.
  12.  

To install:

  1. Install a new insulator in each injector port in the manifold.
  2.  
  3. Remove the old grommet and O-ring from each injector. Install a new grommet and O-ring; coat the O-ring lightly with clean, thin oil.
  4.  
  5. If the fuel pressure regulator was removed, replace the O-ring with a new one and coat it lightly with clean, thin oil. Insert the regulator straight into the rail, then check that it can be rotated freely. If it does not rotate smoothly, remove it and inspect the O-ring for deformation or jamming. When properly installed, align the mounting holes and tighten the retaining bolts to 7 ft. lbs. (9 Nm). This procedure must be followed even if the fuel rail was not removed.
  6.  
  7. Install the injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage.
  8.  
  9. Install the delivery pipe and injectors to the engine. Make certain that each injector fits correctly into its port and that the rubber insulators for the fuel rail mounts are in position.
  10.  
  11. Install the fuel rail retaining bolts and tighten them to 9 ft. lbs. (12 Nm).
  12.  
  13. Connect the wiring harnesses to the appropriate injector.
  14.  
  15. Connect the fuel return hose to the pressure regulator, then connect the vacuum hose.
  16.  
  17. Replace the O-ring on the high pressure fuel line, coat the O-ring lightly with clean, thin oil and install the line to the fuel rail. Tighten the mounting bolts.
  18.  
  19. Attach the PCV hose and the breather hose if they were disconnected.
  20.  
  21. Connect the negative battery cable. Pressurize the fuel system and inspect all connections for leaks.
  22.  

2.0L Engine
  1. Relieve the fuel system pressure as described in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  6.  
  7. Remove or disconnect the following:

    Positive Crankcase Ventilation (PCV) hose
     
    Exhaust Gas Recirculation (EGR) solenoid valve connector
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Purge control solenoid valve connector
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) motor connector
     
    Electrical connector from each injector, label for reference
     
    High pressure fuel hose
     
    Fuel return hose
     
    Vacuum hose(s)
     
    Fuel pressure regulator
     
    Fuel hose
     
    Fuel return pipe
     
    Bolt(s) holding the fuel rail to the manifold. Carefully lift the rail up and remove it with the injectors attached. Take great care not to drop an injector. Place the rail and injectors in a safe location on the workbench; protect the tips of the injectors from dirt and/or impact.
     
    Injector insulators from the intake manifold, discard. The insulators are not reusable.
     
    Injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet and O-ring come off with the injector.

    Click image to see an enlarged view

    Fig. Fuel injectors and related components-Lancer 2.0L engine

     

  8.  

To install:

  1. Install a new insulator in each injector port in the manifold.
  2.  
  3. Remove the old grommet and O-ring from each injector. Install a new grommet and O-ring; coat the O-ring lightly with clean, thin oil.
  4.  
  5. If the fuel pressure regulator was removed, replace the O-ring with a new one and coat it lightly with clean, thin oil. Insert the regulator straight into the rail, then check that it can be rotated freely. If it does not rotate smoothly, remove it and inspect the O-ring for deformation or jamming. When properly installed, align the mounting holes and tighten the retaining bolts to 84 inch lbs. (9 Nm). This procedure must be followed even if the fuel rail was not removed.
  6.  
  7. Install or connect the following:

    Injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage.
     
    Fuel rail and injectors to the engine. Make certain that each injector fits correctly into its port and that the rubber insulators for the fuel rail mounts are in position.
     
    Fuel return pipe and fuel hose
     
    Fuel return hose to the fuel rail
     
    High pressure fuel line to the fuel rail
     
    Fuel injector connectors
     
    IAC motor connector
     
    TP sensor connector
     
    Purge control solenoid connector
     
    MDP sensor connector
     
    EGR solenoid valve connector
     
    PCV hose connector
     
    Negative battery cable
     

  8.  
  9. Pressurize the fuel system and inspect all connections for leaks.
  10.  

2.0L Non-Turbo Engines


Click image to see an enlarged view

Fig. Exploded view of the fuel injection components-1999 2.0L non-turbo engines

  1. Properly relieve the fuel system pressure as outlined earlier in this section.
  2.  
  3. Disconnect the negative (if not already done), and the positive battery cables, then remove the battery from the vehicle.
  4.  
  5. Disconnect the air intake hose.
  6.  
  7. Place a shop rag around the fitting, then detach the high-pressure fuel hose connection. Remove and discard the line O-ring.
  8.  
  9. Unfasten the fuel return hose connection.

    Click image to see an enlarged view

    Fig. After relieving system pressure, loosen the high pressure fuel line



    Click image to see an enlarged view

    Fig. Make sure to place a shop rag under the line to catch any fuel that may seep out after disconnection

  10.  
  11. If necessary, disconnect the pressure regulator vacuum hose and the injector harness connector.

    Click image to see an enlarged view

    Fig. Unplug the fuel injector harness connector

  12.  
  13. Remove the fuel rail from the vehicle with the injectors attached. Be very careful not to drop the assembly. Place the rail and injectors in a safe location on a clean workbench; protect the tips of the injectors from dirt and/or impact.
  14.  
  15. Tag and detach the fuel injector electrical connectors.
  16.  
  17. Unfasten the injector-to-fuel rail retainers, then separate the injectors from the rail.

    Click image to see an enlarged view

    Fig. After the fuel rail is removed, spread the retainer and remove the fuel injector

  18.  
  19. Remove and discard the injector O-rings. There is 1 at each end of the O-ring.

    Click image to see an enlarged view

    Fig. As shown with arrows, there is an O-ring at the end of each injector



    Click image to see an enlarged view

    Fig. The injector O-rings must be discarded and replaced with new ones before installation

  20.  
  21. If necessary to remove the fuel pressure regulator, unfasten the snapring, then remove the pressure regulator from the fuel rail. Remove and discard the regulator O-rings.
  22.  

To install:


WARNING
When lubricating O-rings, do NOT allow any engine oil to get into the fuel rail!

  1. If the regulator was removed, lightly lubricate new O-rings with clean engine oil, then install on he regulator. Position the regulator on the rail, then secure with the snapring.
  2.  
  3. Lightly coat new O-rings with clean engine oil, then install on the injector.
  4.  
  5. Install the injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage. Secure with the injector retainers.
  6.  
  7. Attach the injector electrical connectors, as tagged during removal.
  8.  
  9. Install the fuel rail into the vehicle and install the mounting bolts (if equipped).
  10.  
  11. Attach the injector harness connector and the pressure regulator vacuum hose.
  12.  
  13. Install the fuel return hose connection.
  14.  
  15. Install a new O-ring, then connect the high pressure fuel line. To ease connection, place a small amount of clean engine oil into the hose union before inserting.
  16.  
  17. Connect the air intake hose.
  18.  
  19. Install the battery, then connect the positive and negative battery cables.
  20.  
  21. Pressurize the fuel system by turning the ignition ON and inspect all connections for leaks.
  22.  

2.4L Engine


Click image to see an enlarged view

Fig. Remove the fuel feed line-to-fuel rail retaining fitting bolts . . .



Click image to see an enlarged view

Fig. . . . then remove the fuel feed line from the fuel injector rail



Click image to see an enlarged view

Fig. Remove the hose clamp on the fuel return line . . .



Click image to see an enlarged view

Fig. . . . then disconnect the hose from the pressure regulator



Click image to see an enlarged view

Fig. Remove the vacuum hose from the pressure regulator



Click image to see an enlarged view

Fig. Detach the connectors from all of the fuel injectors



Click image to see an enlarged view

Fig. Remove the two fuel rail retaining bolts . . .



Click image to see an enlarged view

Fig. . . . then lift the rail and the injectors from the intake manifold



Click image to see an enlarged view

Fig. Remove the fuel injectors from the rail by gently rocking them loose



Click image to see an enlarged view

Fig. Always replace the O-rings on the injectors before reinstalling them

  1. Relieve the fuel system pressure as described in this section.
  2.  
  3. Label and disconnect the spark plug wires. Position the wires aside.
  4.  
  5. Disconnect the PCV hose from the valve cover.
  6.  
  7. Remove the bolts holding the high pressure fuel line to the fuel rail, then disconnect the line. Be prepared to contain fuel spillage; plug the line to keep out dirt and debris.
  8.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Remove the vacuum hose from the fuel pressure regulator.
  2.  
  3. Disconnect the fuel return hose from the pressure regulator.
  4.  
  5. Label and detach the electrical connectors from each injector.
  6.  
  7. Remove the bolt(s) holding the fuel rail to the manifold. Carefully lift the rail up and remove it with the injectors attached. Take great care not to drop an injector. Place the rail and injectors in a safe location on the workbench; protect the tips of the injectors from dirt and/or impact.
  8.  
  9. Remove and discard the injector insulators from the intake manifold. The insulators are not reusable.
  10.  
  11. Remove the injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet and O-ring come off with the injector.
  12.  

To install:

  1. Install a new insulator in each injector port in the manifold.
  2.  
  3. Remove the old grommet and O-ring from each injector. Install a new grommet and O-ring; coat the O-ring lightly with clean, thin oil.
  4.  
  5. If the fuel pressure regulator was removed, replace the O-ring with a new one and coat it lightly with clean, thin oil. Insert the regulator straight into the rail, then check that it can be rotated freely. If it does not rotate smoothly, remove it and inspect the O-ring for deformation or jamming. When properly installed, align the mounting holes and tighten the retaining bolts to 7 ft. lbs. (9 Nm). This procedure must be followed even if the fuel rail was not removed.
  6.  
  7. Install the injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage.
  8.  
  9. Install the delivery pipe and injectors to the engine. Make certain that each injector fits correctly into its port and that the rubber insulators for the fuel rail mounts are in position.
  10.  
  11. Install the fuel rail retaining bolts and tighten them to 9 ft. lbs. (12 Nm).
  12.  
  13. Connect the wiring harnesses to the appropriate injector.
  14.  
  15. Connect the fuel return hose to the pressure regulator, then connect the vacuum hose.
  16.  
  17. Replace the O-ring on the high pressure fuel line, coat the O-ring lightly with clean, thin oil and install the line to the fuel rail. Tighten the mounting bolts to 4 ft. lbs. (6 Nm).
  18.  
  19. Connect the PCV hose and spark plug wires.
  20.  
  21. Connect the negative battery cable. Pressurize the fuel system and inspect all connections for leaks.
  22.  

  1. Relieve the fuel system pressure.
  2.  
  3. Label and disconnect the spark plug wires. Position the wires aside.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.



    Positive Crankcase Ventilation (PCV) hose from the valve cover
     
    High pressure fuel line to the fuel rail and disconnect the line. Be prepared to contain fuel spillage; plug the line to keep out dirt and debris.
     

  6.  
  7. Remove or disconnect the following:

    Vacuum hose from the fuel pressure regulator
     
    Fuel return hose from the pressure regulator
     
    Electrical connector from each injector, label for reference
     
    Bolt(s) holding the fuel rail to the manifold. Carefully lift the rail up and remove it with the injectors attached. Take great care not to drop an injector. Place the rail and injectors in a safe location on the workbench; protect the tips of the injectors from dirt and/or impact.
     
    Injector insulators from the intake manifold, discard. The insulators are not reusable.
     
    Injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet and O-ring come off with the injector.
     

  8.  

To install:

  1. Install a new insulator in each injector port in the manifold.
  2.  
  3. Remove the old grommet and O-ring from each injector. Install a new grommet and O-ring; coat the O-ring lightly with clean, thin oil.
  4.  
  5. If the fuel pressure regulator was removed, replace the O-ring with a new one and coat it lightly with clean, thin oil. Insert the regulator straight into the rail, then check that it can be rotated freely. If it does not rotate smoothly, remove it and inspect the O-ring for deformation or jamming. When properly installed, align the mounting holes and tighten the retaining bolts to 84 inch lbs. (9 Nm). This procedure must be followed even if the fuel rail was not removed.
  6.  
  7. Install or connect the following:

    Injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage.
     
    Delivery pipe and injectors to the engine. Make certain that each injector fits correctly into its port and that the rubber insulators for the fuel rail mounts are in position.
     
    Fuel rail retaining bolts and tighten them to 108 inch lbs. (12 Nm)
     
    Wiring harnesses to the appropriate injector
     
    Fuel return hose to the pressure regulator, then connect the vacuum hose
     
    O-ring on the high pressure fuel line, coat the O-ring lightly with clean, thin oil and install the line to the fuel rail. Tighten the mounting bolts to 48 inch lbs. (6 Nm).
     
    PCV hose and spark plug wires
     
    Negative battery cable
     

  8.  
  9. Pressurize the fuel system and inspect all connections for leaks.
  10.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable. Drain the engine coolant. Remove the air cleaner assembly.
  4.  
  5. Disconnect the accelerator cable connection. Disconnect the throttle position sensor connector. Disconnect the idle air control motor connector. Disconnect the vacuum hose connection.
  6.  
  7. Disconnect the water hose connection. Remove the throttle body retaining bolts. Remove the throttle body from its mounting. Discard the gasket.
  8.  
  9. Disconnect the PCV hose connection, ignition coil connector and injector connector.
  10.  
  11. Disconnect the ignition failure sensor connector. Disconnect the high pressure fuel hose connection. Disconnect the hose connection.
  12.  
  13. Disconnect the vacuum hose connection. Remove the fuel pressure regulator. Remove the fuel rail, insulators and injectors. Discard the O-rings.
  14.  

To install:

  1. Installation is the reverse of the removal procedure. Be sure to use new O-rings and gaskets as required.
  2.  
  3. Start the engine and check for leaks, correct as required.
  4.  

  1. Relieve the fuel system pressure.
  2.  
  3. Label and disconnect the spark plug wires. Position the wires aside.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.



    Positive Crankcase Ventilation (PCV) hose from the valve cover
     
    High pressure fuel line to the fuel rail and disconnect the line. Be prepared to contain fuel spillage; plug the line to keep out dirt and debris.
     

  6.  
  7. Remove or disconnect the following:

    Vacuum hose from the fuel pressure regulator
     
    Fuel return hose from the pressure regulator
     
    Electrical connector from each injector, label for reference
     
    Bolt(s) holding the fuel rail to the manifold. Carefully lift the rail up and remove it with the injectors attached. Take great care not to drop an injector. Place the rail and injectors in a safe location on the workbench; protect the tips of the injectors from dirt and/or impact.
     
    Injector insulators from the intake manifold, discard. The insulators are not reusable.
     
    Injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet and O-ring come off with the injector.
     

  8.  

To install:

  1. Install a new insulator in each injector port in the manifold.
  2.  
  3. Remove the old grommet and O-ring from each injector. Install a new grommet and O-ring; coat the O-ring lightly with clean, thin oil.
  4.  
  5. If the fuel pressure regulator was removed, replace the O-ring with a new one and coat it lightly with clean, thin oil. Insert the regulator straight into the rail, then check that it can be rotated freely. If it does not rotate smoothly, remove it and inspect the O-ring for deformation or jamming. When properly installed, align the mounting holes and tighten the retaining bolts to 84 inch lbs. (9 Nm). This procedure must be followed even if the fuel rail was not removed.
  6.  
  7. Install or connect the following:

    Injector into the fuel rail, constantly turning the injector left and right during installation. When fully installed, the injector should still turn freely in the rail. If it does not, remove the injector and inspect the O-ring for deformation or damage.
     
    Delivery pipe and injectors to the engine. Make certain that each injector fits correctly into its port and that the rubber insulators for the fuel rail mounts are in position.
     
    Fuel rail retaining bolts and tighten them to 108 inch lbs. (12 Nm)
     
    Wiring harnesses to the appropriate injector
     
    Fuel return hose to the pressure regulator, then connect the vacuum hose
     
    O-ring on the high pressure fuel line, coat the O-ring lightly with clean, thin oil and install the line to the fuel rail. Tighten the mounting bolts to 48 inch lbs. (6 Nm).
     
    PCV hose and spark plug wires
     
    Negative battery cable
     

  8.  
  9. Pressurize the fuel system and inspect all connections for leaks.
  10.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable. Remove the air cleaner cover and air intake hose assembly.
  4.  
  5. Disconnect the PCV valve hose connection, ignition coil connectors, EGR valve connector and fuel injector connectors.
  6.  
  7. Disconnect the throttle position sensor connector, manifold absolute pressure sensor connector, EVAP emission purge solenoid connector and knock sensor connector.
  8.  
  9. Disconnect the power steering pressure switch connector. Remove the rocker cover bracket bolts.
  10.  
  11. Disconnect the high pressure hose connection. Remove the fuel rail, insulators, grommets and injectors. Discard the O-rings.
  12.  

To install:

  1. Installation is the reverse of the removal procedure. Be sure to use new O-rings and gaskets as required.
  2.  
  3. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  4.  
  5. Turn the ignition switch to the ON position.
  6.  
  7. Select -check mode- from the menu screen.
  8.  
  9. Select -erase memory- from the menu screen.
  10.  
  11. Initialize the learning value.
  12.  
  13. Start the engine and check for leaks, correct as required.
  14.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable. Remove the air cleaner cover and air intake hose assembly.
  4.  
  5. Disconnect the PCV valve hose connection, capacitor connector, ignition coil connectors, EGR valve connector and fuel injector connectors.
  6.  
  7. Remove the rocker cover bracket bolts. Disconnect the high pressure hose connection.
  8.  
  9. Remove the fuel rail, insulators, grommets and injectors. Discard the O-rings.
  10.  

To install:

  1. Installation is the reverse of the removal procedure. Be sure to use new O-rings and gaskets as required.
  2.  
  3. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  4.  
  5. Turn the ignition switch to the ON position.
  6.  
  7. Select -check mode- from the menu screen.
  8.  
  9. Select -erase memory- from the menu screen.
  10.  
  11. Initialize the learning value.
  12.  
  13. Start the engine and check for leaks, correct as required.
  14.  

3.0L And 3.5L Engines


Click image to see an enlarged view

Fig. Exploded view of the fuel injectors and related components-3.0L engines



Click image to see an enlarged view

Fig. Exploded view of the fuel injectors and related components-3.5L engine

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
Work MUST NOT be started until at least 90 seconds after the ignition switch is turned to the LOCK position and the negative battery cable is disconnected from the battery. This will allow time for the air bag system backup power supply to deplete its stored energy, preventing accidental air bag deployment which could result in unnecessary air bag system repairs and/or personal injury.

  1. Drain the cooling system.
  2.  
  3. Disconnect all components from the air intake plenum and remove the plenum from the intake manifold. Refer to Section 3.
  4.  
  5. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
  6.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect the fuel return hose and remove the O-ring.
  2.  
  3. Disconnect the vacuum hose from the fuel pressure regulator.
  4.  
  5. Detach the electrical connectors from each injector.
  6.  
  7. Remove the fuel pipe connecting the fuel rails. Remove the injector rail retaining bolts. Make sure the rubber mounting bushings do not get lost.
  8.  
  9. Lift the rail assemblies up and away from the engine.
  10.  
  11. Remove the injectors from the rail by pulling gently. Discard the lower insulator.
  12.  

To install:


NOTE
Some of the vehicles may have a clip that secures the injector to the fuel rail. Be sure to remove or install the injector clip where necessary.

  1. Install a new grommet and O-ring to the injector. Coat the O-ring with light oil.
  2.  
  3. Install the injector to the fuel rail.
  4.  
  5. Replace the seats in the intake manifold. Install the fuel rails and injectors to the manifold. Make sure the rubber bushings are in place before tightening the mounting bolts.
  6.  
  7. Tighten the retaining bolts to 7-9 ft. lbs. (10-13 Nm). Install the fuel pipe with new gasket.
  8.  
  9. Attach the electrical connectors to the injectors.
  10.  
  11. Connect the fuel return hose.
  12.  
  13. Replace the O-ring, lightly lubricate it and connect the high pressure fuel line.
  14.  
  15. Using new gaskets, install the intake plenum and all related items. Refer to Section 3.
  16.  
  17. Fill the cooling system.
  18.  
  19. Connect the negative battery cable and check the entire system for proper operation and leaks.
  20.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    Work MUST NOT be started until at least 90 seconds after the ignition switch is turned to the LOCK position and the negative battery cable is disconnected from the battery. This will allow time for the air bag system backup power supply to deplete its stored energy preventing accidental air bag deployment which could result in unnecessary air bag system repairs and/or personal injury.

  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect all components from the air intake plenum and remove the plenum from the intake manifold.
  8.  
  9. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  10.  
  11. Remove or disconnect the following:

    Fuel return hose and remove the O-ring
     
    Vacuum hose from the fuel pressure regulator
     
    Electrical connectors from each injector
     
    Fuel pipe connecting the fuel rails
     
    Injector rail retaining bolts. Make sure the rubber mounting bushings do not get lost.
     

  12.  
  13. Lift the rail assemblies up and away from the engine.
  14.  
  15. Remove the injectors from the rail by pulling gently. Discard the lower insulator.
  16.  

To install:


NOTE
Some of the vehicles may have a clip that secures the injector to the fuel rail. Be sure to remove or install the injector clip where necessary.

  1. Install or connect the following:

    New grommet and O-ring to the injector. Coat the O-ring with light oil.
     
    Injector to the fuel rail
     

  2.  
  3. Replace the seats in the intake manifold. Install the fuel rails and injectors to the manifold. Make sure the rubber bushings are in place before tightening the mounting bolts.
  4.  
  5. Tighten the retaining bolts to 84-108 inch lbs. (10-13 Nm). Install the fuel pipe with new gasket.
  6.  
  7. Install or connect the following:

    Electrical connectors to the injectors
     
    Fuel return hose
     
    O-ring, lightly lubricate it and connect the high pressure fuel line
     
    Intake plenum and all related items, using new gaskets
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Connect the negative battery cable and check the entire system for proper operation and leaks.
  12.  

3.0L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    Work MUST NOT be started until at least 90 seconds after the ignition switch is turned to the LOCK position and the negative battery cable is disconnected from the battery. This will allow time for the air bag system backup power supply to deplete its stored energy preventing accidental air bag deployment which could result in unnecessary air bag system repairs and/or personal injury.

  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect all components from the air intake plenum and remove the plenum from the intake manifold.
  8.  
  9. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  10.  
  11. Remove or disconnect the following:

    Fuel return hose and remove the O-ring
     
    Vacuum hose from the fuel pressure regulator
     
    Electrical connectors from each injector
     
    Fuel pipe connecting the fuel rails
     
    Injector rail retaining bolts. Make sure the rubber mounting bushings do not get lost.
     

  12.  
  13. Lift the rail assemblies up and away from the engine.
  14.  
  15. Remove the injectors from the rail by pulling gently. Discard the lower insulator.
  16.  

To install:


NOTE
Some of the vehicles may have a clip that secures the injector to the fuel rail. Be sure to remove or install the injector clip where necessary.

  1. Install or connect the following:

    New grommet and O-ring to the injector. Coat the O-ring with light oil.
     
    Injector to the fuel rail
     

  2.  
  3. Replace the seats in the intake manifold. Install the fuel rails and injectors to the manifold. Make sure the rubber bushings are in place before tightening the mounting bolts.
  4.  
  5. Tighten the retaining bolts to 84-108 inch lbs. (10-13 Nm). Install the fuel pipe with new gasket.
  6.  
  7. Install or connect the following:

    Electrical connectors to the injectors
     
    Fuel return hose
     
    O-ring, lightly lubricate it and connect the high pressure fuel line
     
    Intake plenum and all related items, using new gaskets
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Connect the negative battery cable and check the entire system for proper operation and leaks.
  12.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    Work MUST NOT be started until at least 90 seconds after the ignition switch is turned to the LOCK position and the negative battery cable is disconnected from the battery. This will allow time for the air bag system backup power supply to deplete its stored energy preventing accidental air bag deployment which could result in unnecessary air bag system repairs and/or personal injury.

  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect all components from the air intake plenum and remove the plenum from the intake manifold.
  8.  
  9. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  10.  
  11. Remove or disconnect the following:

    Fuel return hose and remove the O-ring
     
    Vacuum hose from the fuel pressure regulator
     
    Electrical connectors from each injector
     
    Fuel pipe connecting the fuel rails
     
    Injector rail retaining bolts. Make sure the rubber mounting bushings do not get lost.
     

  12.  
  13. Lift the rail assemblies up and away from the engine.
  14.  
  15. Remove the injectors from the rail by pulling gently. Discard the lower insulator.
  16.  

To install:


NOTE
Some of the vehicles may have a clip that secures the injector to the fuel rail. Be sure to remove or install the injector clip where necessary.

  1. Install or connect the following:

    New grommet and O-ring to the injector. Coat the O-ring with light oil.
     
    Injector to the fuel rail
     

  2.  
  3. Replace the seats in the intake manifold. Install the fuel rails and injectors to the manifold. Make sure the rubber bushings are in place before tightening the mounting bolts.
  4.  
  5. Tighten the retaining bolts to 84-108 inch lbs. (10-13 Nm). Install the fuel pipe with new gasket.
  6.  
  7. Install or connect the following:

    Electrical connectors to the injectors
     
    Fuel return hose
     
    O-ring, lightly lubricate it and connect the high pressure fuel line
     
    Intake plenum and all related items, using new gaskets
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Connect the negative battery cable and check the entire system for proper operation and leaks.
  12.  

3.8L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable. Remove the intake manifold plenum assembly.
  4.  
  5. Disconnect the fuel injector connectors. Remove the control wiring harness bracket mounting bolts. Remove the engine mounting stay.
  6.  
  7. Disconnect the high pressure fuel hose connection. Remove the fuel rail and fuel injector assembly
  8.  
  9. Remove the insulators, O-rings and fuel injectors. Discard the gaskets and O-rings.
  10.  

To install:

Click image to see an enlarged view

Fig. Fuel injectors and related components-3.8L engine

  1. Installation is the reverse of the removal procedure. Be sure to use new O-rings and gaskets as required.
  2.  
  3. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  4.  
  5. Turn the ignition switch to the ON position.
  6.  
  7. Select -check mode- from the menu screen.
  8.  
  9. Select -erase memory- from the menu screen.
  10.  
  11. Initialize the learning value.
  12.  
  13. Start the engine and check for leaks, correct as required.
  14.  

Evolution
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the strut tower bar. Remove the air hose, air by pass hose and air pipe.
  6.  
  7. Disconnect the control harness connector, accelerator cable assembly connection and the injector connector.
  8.  
  9. Disconnect the high pressure fuel hose. Disconnect the fuel return hose. Disconnect the vacuum hose connection.
  10.  
  11. Remove the fuel pressure regulator, discard the O-ring. Remove the fuel return pipe.
  12.  
  13. Remove the fuel rail, insulators and injectors.

    Click image to see an enlarged view

    Fig. Fuel injectors and related components-Evolution

  14.  

To install:

  1. Installation is the reverse of the removal procedure. Be sure to use new O-rings and gaskets as required.
  2.  

 
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