PT Cruiser, 2001 - 2005

Fuel Injectors

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Removal & Installation



Except Turbocharged Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Remove the air cleaner lid
     
    Inlet Air Temperature (IAT) sensor and the make-up hose
     
    Engine cover or throttle control shield, if equipped
     
    Fuel supply tube from fuel rail
     
    Intake manifold
     
    Fuel injector electrical connectors
     
    Fuel rail with the fuel injectors
     
    Fuel injector(s) and discard the O-rings

    Click image to see an enlarged view

    Fig. Remove the fuel rail and injectors as an assembly

     

  6.  

To install:


NOTE
Lubricate the O-rings with clean engine oil.

  1. Install or connect the following:

    Fuel injector(s) to the fuel rail using new O-rings
     
    Fuel injector nozzles into the intake manifold and torque the fuel rail bolts to 8 ft. lbs. (12 Nm)
     
    Fuel injector electrical connectors
     
    Fuel supply tube to fuel rail
     
    Intake manifold
     
    Engine cover or throttle control shield, if equipped
     
    IAT sensor and make-up hose
     
    Air cleaner lid
     
    Negative battery cable
     

  2.  
  3. Start the vehicle and check for leaks, repair if necessary.
  4.  

Turbocharged Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Throttle body inlet hose from the throttle body
     
    Purge hose from the throttle body
     
    Electrical connections from the throttle body
     
    Throttle control shield
     
    Accelerator and cruise control cable from the throttle body
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Vacuum lines from the rear of the intake manifold
     
    5 bolts from the front and 2 bolts from the rear of the intake manifold
     
    Intake manifold and cover the lower manifold to avoid contamination
     
    Upper radiator hose up and out of the way
     
    2 small hoses from the thermostat housing
     
    2 bolts from the thermostat housing and rotate the assembly up and out of the way
     
    Fuel lines from the rail
     
    Fuel injector electrical connectors and wire from the rail
     
    Fuel rail with the fuel injectors
     
    Fuel injector(s) and discard the O-rings
     

  8.  

To install:


NOTE
Lubricate the O-rings with clean engine oil.

  1. Install or connect the following:

    Fuel injector(s) to the fuel rail using new O-rings
     
    Fuel injector nozzles into the intake manifold and torque the fuel rail bolts to 170 inch lbs. (19 Nm)
     
    Fuel injector electrical connectors and wiring to the fuel rail
     
    Fuel line to fuel rail
     
    Rotate the thermostat assembly into position and tighten the 2 bolts
     
    2 small hoses to the thermostat housing
     
    Upper radiator hose
     
    Intake manifold
     
    5 bolts front and 2 rear bolts on the intake manifold
     
    Vacuum lines to the rear of the intake manifold
     
    MAP sensor connector
     
    Accelerator and cruise control cable to the throttle body
     
    Throttle control shield
     
    Electrical connections to the throttle body
     
    Purge hose to the throttle body
     
    Throttle body inlet hose to the throttle body
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

 
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