PT Cruiser 2006-2007

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



Non-Turbo 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:

    The negative battery cable
     
    The air cleaner lid
     
    The Inlet Air Temperature (IAT) sensor and the make-up hose
     
    The engine cover or throttle control shield, if equipped
     
    The fuel supply tube from fuel rail
     
    The intake manifold
     
    The fuel injector electrical connectors
     
    The fuel rail with the fuel injectors
     
    The 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:

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

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

Turbo 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:

    The negative battery cable
     
    The throttle body inlet hose from the throttle body
     
    The purge hose from the throttle body
     
    The electrical connections from the throttle body
     
    The throttle control shield
     
    The accelerator and cruise control cable from the throttle body
     
    The Manifold Absolute Pressure (MAP) sensor connector
     
    The vacuum lines from the rear of the intake manifold
     
    The 5 bolts from the front and 2 bolts from the rear of the intake manifold
     
    The intake manifold and cover the lower manifold to avoid contamination
     
    The upper radiator hose up and out of the way
     
    The 2 small hoses from the thermostat housing
     
    The 2 bolts from the thermostat housing and rotate the assembly up and out of the way
     
    The fuel lines from the rail
     
    The fuel injector electrical connectors and wire from the rail
     
    The fuel rail with the fuel injectors
     
    The 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:

    The fuel injector(s) to the fuel rail using new O-rings
     
    The fuel injector nozzles into the intake manifold and torque the fuel rail bolts to 170 inch lbs. (19 Nm)
     
    The fuel injector electrical connectors and wiring to the fuel rail
     
    The fuel line to fuel rail
     
    Rotate the thermostat assembly into position and tighten the 2 bolts
     
    The 2 small hoses to the thermostat housing
     
    The upper radiator hose
     
    The intake manifold
     
    The 5 bolts front and 2 rear bolts on the intake manifold
     
    The vacuum lines to the rear of the intake manifold
     
    The MAP sensor connector
     
    The accelerator and cruise control cable to the throttle body
     
    The throttle control shield
     
    The electrical connections to the throttle body
     
    The purge hose to the throttle body
     
    The throttle body inlet hose to the throttle body
     
    The 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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