2.0L, 2.4L
| WARNING | Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death. |
Scheme 85
Note. Wrap shop towels around hose to catch any gasoline spillage.
Scheme 86
Scheme 87
Scheme 88
Scheme 89
Scheme 90
Scheme 91
Scheme 92
- Release the fuel system pressure.
- Disconnect the negative battery cable.
- Disconnect the fuel line from the fuel rail. Refer to «FITTING-QUICK CONNECT»(ref-305833-S09560237292008120200000) .
- Fuel line removed from the fuel rail.
- Unlock and disconnect the electrical connectors from the fuel injectors.
- Remove the wiring harness from the fuel rail studs.
- Remove the 2 bolts from the fuel rail.
- Remove the fuel rail and injectors from the intake manifold.
- Fuel rail removed from intake manifold.
- Remove fuel injectors from fuel rail.
Scheme 93
| WARNING | Release fuel system pressure before servicing fuel rail. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. |
Scheme 94
- Release fuel system pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE PROCEDURE»(ref-305833-S36254172112008120200000) .
- Disconnect the negative battery cable.
- Remove intake manifold. Refer to «REMOVAL»(ref-305761-S12867644882008120200000) . Refer to «REMOVAL»(ref-305762-S23640210492008120200000) . Refer to «REMOVAL»(ref-305763-S05167891032008120200000) .
- Cover intake manifold to prevent foreign material from entering engine.
- Disconnect fuel supply tube quick connect fitting at the rear of the fuel rail. Refer to «FITTING-QUICK CONNECT»(ref-305833-S09560237292008120200000) .
- If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder.
- Remove electrical connectors from the fuel injectors.
- Remove mounting bolts on both sides of fuel rail.
- Lift fuel rail straight up off of cylinder head.
- Remove retaining clips from fuel injectors at fuel rail.
- Remove fuel injector from fuel rail.
Scheme 95
| WARNING | The fuel system is under a constant pressure (even with the engine off). Before servicing any part on the fuel system, the fuel system pressure must be released. |
Scheme 96
Scheme 97
Scheme 98
Scheme 99
Scheme 100
- Release fuel pressure, see «STANDARD PROCEDURE»(ref-305833-S03943541792008120200000) .
- Disconnect and isolate negative battery cable at battery.
- Remove the upper intake manifold. Refer to «REMOVAL»(ref-305761-S12867644882008120200000) . Refer to «REMOVAL»(ref-305762-S23640210492008120200000) . Refer to «REMOVAL»(ref-305763-S05167891032008120200000) .
- Disconnect the quick connect fuel line from the fuel rail. NOTE: Mark fuel injector electrical harness connectors with correct corresponding cylinder numbers.
- Disconnect all fuel injector electrical connectors (1) from fuel injectors (2).
- Remove fuel rail mounting bolts from fuel rail and lower intake manifold. NOTE: Gently rock the fuel rail and injectors back and forth to loosen the seals on the fuel injectors from the cylinder heads. CAUTION: Do Not use excessive force or prying tools to remove fuel rail and injectors. Damage to the fuel rail and injectors may result.
- Lift fuel rail straight up off of the cylinder heads.
- Drain any excess fuel from the fuel rail into an approved fuel storage container. NOTE: Mark or tag each fuel injector with correct corresponding cylinder numbers
- Remove retaining clips (5) from fuel injectors (2) at fuel rail (4).
- Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
- Install the fuel injectors to the fuel rail.
- Install injector into cup of fuel rail.
- Install retaining clip and check to ensure injector is properly captured. Fuel rail assembly.
- Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
- Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 27 N.m (20 ft. lbs.).
- Install the wiring harness to the fuel rail.
- Connect and lock the electrical connectors to the fuel injectors.
- Connect the fuel line to the fuel rail. Refer to «FITTING-QUICK CONNECT»(ref-305833-S09560237292008120200000) .
- Connect the negative battery cable.
- Use the Scan Tool Fuel System Test to pressurize the fuel system. Check for leaks.