QuestionKevin,
I'm trying to remove the fuel rail to a clogged injector and leaking o-ring. To get at the rail, I feel like I need to remove the lower intake manifold, but can't figure out how. I'm using a Chilton manual to assist but it doesn't specify. Can you help? Right now I have the upper intake manifold off and the throttle body. I've drained the coolant, etc. Any help would be greatly appreciated.
r/
tsw
AnswerREMOVAL
2.4L
WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.
The fuel rail can be removed without removing the intake manifold if the following procedures are followed.
Remove fuel tank filler tube cap.
Perform Fuel System Pressure Release Procedure.
Remove negative battery cable at battery.
Remove air duct at throttle body.
Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to Quick-Connect Fittings.
Remove necessary vacuum lines at throttle body.
Drain engine coolant and remove thermostat and thermostat housing.
Remove PCV hose and valve at valve cover.
Remove 3 upper intake manifold mounting bolts (FUEL RAIL MOUNTING-2.4L), but only loosen 2 lower bolts about 2 turns.
Disconnect 2 main engine harness connectors at rear of intake manifold (MAP SENSOR LOCATION-2.4L).
Disconnect 2 injection wiring harness clips at harness mounting bracket (FUEL RAIL MOUNTING-2.4L).
Disconnect electrical connectors at all 4 fuel injectors. To remove connector refer to (REMOVE/INSTALL INJECTOR CONNECTOR). Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
Remove 2 injection rail mounting bolts (FUEL RAIL-2.4L).
Gently rock and pull fuel rail until fuel injectors just start to clear machined holes in intake manifold.
Remove fuel rail (with injectors attached) from intake manifold.
If fuel injectors are to be removed, refer to Fuel Injector Removal/Installation.
3.7L
WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube (FUEL RAIL REMOVE/INSTALL - 3.7L). Due to design of tube, it does not use any clamps. Never attempt to install a clamping device of any kind to tube. When removing fuel rail assembly for any reason, be careful not to bend or kink tube.
Remove fuel tank filler tube cap.
Perform Fuel System Pressure Release Procedure.
Remove negative battery cable at battery.
Remove air duct at throttle body air box.
Remove air box at throttle body.
Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to Quick-Connect Fittings.
Remove necessary vacuum lines at throttle body.
Disconnect electrical connectors at all 6 fuel injectors. To remove connector refer to (REMOVE/INSTALL INJECTOR CONNECTOR). Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
Disconnect electrical connectors at throttle body sensors.
Remove 6 ignition coils. Refer to Ignition Coil Removal/Installation.
Remove 4 fuel rail mounting bolts (FUEL RAIL REMOVE/INSTALL - 3.7L) .
Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
Remove fuel rail (with injectors attached) from engine.
If fuel injectors are to be removed, refer to Fuel Injector
