Sebring 2006

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative cable from the battery.
  4.  
  5. Remove the wiring harness from the fuel rail support bracket.
  6.  
  7. Remove the fuel rail support bracket.
  8.  
  9. Disconnect the wiring connectors for the fuel injectors harness.
  10.  
  11. Remove the wiring harness from the fuel rail brackets.
  12.  
  13. Disconnect the connectors from the fuel injectors.
  14.  
  15. Remove the throttle and speed control cables from the fuel rail.
  16.  
  17. Remove the fuel hose quick connect fitting from the chassis tube. Place a shop towel under the connections to absorb any fuel spilled from the fitting.
    CAUTION
    Wrap a shop towel around hoses to catch any gasoline spillage.

  18.  
  19. Remove the fuel rail attaching bolts.
  20.  
  21. Remove the fuel rail. Be careful not to damage the injector O-rings upon removal from their ports.
  22.  
  23. Position the fuel rail assembly so that the fuel injectors are easily accessible.
  24.  
  25. Remove the injector clip and pull the injector out of the fuel rail.
  26.  
  27. Check the injector O-ring for damage. If the O-ring is damaged, it must be replaced. Replace the injector clip if it is damaged.
  28.  
  29. Repeat the removal procedure for the remaining injectors.

    Click image to see an enlarged view

    Fig. Fuel rail and bracket-2.4L engine



    Click image to see an enlarged view

    Fig. Fuel injector and rail-2.4L engine

  30.  

To install:

  1. Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation.
  2.  
  3. Install the injector clip by sliding the open end into the top slot of the injector. The edge of the receiver cup will slide into the side slots of the clip.
  4.  
  5. Install the injector top end into the fuel rail receiver cap. Be careful not to damage the O-ring during installation.
  6.  
  7. Repeat steps for remaining injectors.
  8.  
  9. Ensure injector holes are clean. Replace the O-rings if damaged.
  10.  
  11. Lubricate the injector O-rings with a drop of clean engine oil to ease installation.
  12.  
  13. Put the tip of each injector into its port. Push the assembly into place until the injectors are seated in the ports.
  14.  
  15. Install the 2 fuel rail mounting bolts to the intake manifold. Tighten the bolts to 105 inch lbs. (12 Nm).
  16.  
  17. Install the fuel rail mounting bolt to the cylinder head. Tighten the bolt to 16 ft. lbs. (22 Nm).
  18.  
  19. Connect the connectors to the fuel injectors.
  20.  
  21. Install the fuel rail support bracket and loosely install all the bolts.
  22.  
  23. Tighten 3 fasteners to the intake manifold to 21 ft. lbs. (28 Nm).
  24.  
  25. Tighten 2 bolts to the fuel rail to 75 inch lbs. (9 Nm).
  26.  
  27. Install the wiring harness to the brackets.
  28.  
  29. Connect the throttle and speed control cables to the fuel rail bracket.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Use a scan tool to pressurize the fuel system. Check for leaks.
  34.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  6.  
  7. Remove or disconnect the following:
    NOTE
    Cover the intake manifold openings to keep dirt from entering the system.



    The fuel supply line quick-connect fitting from the fuel rail
     
    The upper intake manifold plenum and discard the gasket
     
    The fuel injector electrical connectors
     
    The fuel rail from the intake manifold
     



    The fuel injector clip
     
    The fuel injector(s) from the fuel rail and discard the O-rings

    Click image to see an enlarged view

    Fig. View of the fuel rail assembly-2.7L engine

     

  8.  

To install:

  1. Install or connect the following:
    NOTE
    Be sure the spacers are located under the fuel rail



    The fuel injector to the fuel rail using new O-rings lubricated with engine oil
     
    The fuel injector clip
     
    The fuel rail and torque the bolts to 96 inch lbs. (12 Nm)
     



    The fuel injector electrical connectors
     
    The fuel supply line quick-connect fitting to the fuel rail
     
    The upper intake manifold plenum using a new gasket and torque the bolts to 13 ft. lbs. (18 Nm)
     
    The throttle cables
     
    The sensor electrical connectors
     
    The negative battery cable
     

  2.  
  3. Use a scan tool and run an Automatic Shutdown (ASD) fuel system test to pressurize the fuel system. Check for leaks and make any necessary repairs.
  4.  

 
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