PT Cruiser, 2001 - 2005

Fuel Injector Rail (Fuel Supply Manifold)

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Removal & Installation



Except Turbocharged Models

WARNING
Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.

  1. Release fuel system pressure.
  2.  
  3. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
  4.  
  5. Remove the negative battery cable.
  6.  
  7. Remove the engine cover or throttle control shield if equipped.
    NOTE
    Wrap shop towels around hose to catch any gasoline spillage.

  8.  
  9. Disconnect fuel supply tube from rail.
  10.  
  11. Remove the Intake Manifold, refer to the Engine section.
  12.  
  13. Disconnect electrical connectors from fuel injectors.
  14.  
  15. Remove bolts holding fuel rail.
  16.  
  17. Remove the fuel rail and injectors.
  18.  
  19. Remove the injectors from the fuel rail.
  20.  

To install:

  1. Install injectors to the fuel rail.
  2.  
  3. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
  4.  
  5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
  6.  
  7. Attach electrical connectors to fuel injectors.
  8.  
  9. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section
  10.  
  11. Install Intake Manifold, refer to the Engine section.
  12.  
  13. Install the engine cover or throttle control shield if equipped.
  14.  
  15. Install the negative battery cable.
  16.  
  17. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Tighten air inlet tube clamps to 20-30 inch lbs. (2-4 Nm).
  18.  

Turbocharged Models

WARNING
Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.

  1. Release the fuel system pressure. Refer to Fuel System Pressure Release procedure in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the throttle body inlet hose and remove from throttle body.
  6.  
  7. Disconnect the purge hose from the throttle body.
  8.  
  9. Unlock and disconnect the electrical connection at the throttle body.
  10.  
  11. Remove the throttle control shield .
  12.  
  13. Remove the throttle and speed control cables from the throttle body.
  14.  
  15. Remove the cables from the throttle body bracket.
  16.  
  17. Unlock and disconnect the MAP sensor electrical connector.
  18.  
  19. Remove the vacuum lines from the rear of the intake manifold.
  20.  
  21. Remove the 5 bolts from the front of the intake manifold.
  22.  
  23. Remove the 2 bolts from the rear of the intake manifold.
  24.  
  25. Remove the intake manifold. Cover the lower intake manifold openings.
  26.  
  27. Drain the Coolant system.
  28.  
  29. Move the upper radiator hose clamp, so that the hose can be rotated up and out of the way.
  30.  
  31. Remove the 2 small hoses from the thermostat housing.
  32.  
  33. Remove the 2 bolts from the thermostat housing and rotate the assembly up and out of the way.
    NOTE
    Wrap shop towels around hose to catch any gasoline spillage.

  34.  
  35. Disconnect the fuel line from the fuel rail.
  36.  
  37. Unlock and disconnect the electrical connectors from the fuel injectors.
  38.  
  39. Remove the wiring harness from the fuel rail.
  40.  
  41. Remove the 2 bolts from the fuel rail.
  42.  
  43. Remove the fuel rail and injectors from the intake manifold.
  44.  

To install:

  1. Install the fuel injectors to the fuel rail.
  2.  
  3. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
  4.  
  5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
  6.  
  7. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
  8.  
  9. Install the wiring harness to the fuel rail.
  10.  
  11. Connect and lock the electrical connectors to the fuel injectors.
  12.  
  13. Connect the fuel line to the fuel rail.
  14.  
  15. Rotate the assembly back into place and install the 2 bolts to the thermostat housing tighten to 110 inch lbs. (12.5 Nm).
  16.  
  17. Move the upper radiator house clamp back into place.
  18.  
  19. Install the 2 small hoses to the thermostat housing.
  20.  
  21. Fill the Coolant system.
  22.  
  23. Install the intake manifold.
  24.  
  25. Install the 2 bolts to the rear of the intake manifold tighten to 250 inch lbs. (28 Nm).
  26.  
  27. Install the 5 bolts to the front of the intake manifold and tighten to 250 inch lbs. (28 Nm).
  28.  
  29. Install the vacuum lines to the rear of the intake manifold.
  30.  
  31. Connect and lock the MAP sensor electrical connector.
  32.  
  33. Install the cables to the throttle body bracket.
  34.  
  35. Install the throttle and speed control cables to the throttle body.
  36.  
  37. Install the throttle control shield.
  38.  
  39. Connect and lock the electrical connections at the throttle body.
  40.  
  41. Connect the purge hose to the throttle body.
  42.  
  43. Connect the throttle body inlet hose to the throttle body and tighten clamps to 20-30 inch lbs. (2-4 Nm).
  44.  
  45. Connect the negative battery cable.
  46.  
  47. Use the DRB® scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
  48.  

 
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