Fuel Rail: Removal: 2.4L

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED.

Fig 1: MAP SENSOR LOCATION - 2.4L

Courtesy of DAIMLERCHRYSLER CORP.

1 - REAR OF INTAKE MANIFOLD

2 - MAP SENSOR

3 - ALIGNMENT PIN

4 - MOUNTING BOLT (TORX)

5 - ELECTRICAL CONNECTOR

6 - MAIN ENGINE HARNESS CONNECTORS

Fig 2: FUEL RAIL MOUNTING - 2.4L

Courtesy of DAIMLERCHRYSLER CORP.

1 - FUEL RAIL

2 - INJECTION HARNESS CLIPS

3 - LOWER MOUNTING HOLES

4 - UPPER MOUNTING HOLES

5 - INTAKE MANIFOLD

The fuel rail can be removed without removing the intake manifold if the following procedures are followed.

Remove fuel tank filler tube cap.
Perform STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE .
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 FITTING .
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, but only loosen 2 lower bolts about 2 turns. See Fig 2.
Disconnect 2 main engine harness connectors at rear of intake manifold. See Fig 1.
Disconnect 2 injection wiring harness clips at harness mounting bracket. See Fig 2.
Disconnect electrical connectors at all 4 fuel injectors. To remove connector refer to Figure. 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. See Figure.
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 .