Fuel Rail: Removal: 2.4L

Fig 1: Locating MAP Sensor - 2.4L

Courtesy of DAIMLERCHRYSLER CORP.

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

Fig 2: Identifying Fuel Rail Mounting - 2.4L

Courtesy of DAIMLERCHRYSLER CORP.

1. Remove fuel tank filler tube cap.
2. Perform PRESSURE RELEASE  procedure.
3. Remove negative battery cable at battery.
4. Remove air duct at throttle body.
5. Disconnect fuel line latch clip and fuel line at fuel rail. See QUICK CONNECT FITTING . A special tool will be necessary for fuel line disconnection.
6. Remove necessary vacuum lines at throttle body.
7. Drain engine coolant and remove thermostat and thermostat housing.
8. Remove PCV hose and valve at valve cover.
9. Remove 3 upper intake manifold mounting bolts, but only loosen 2 lower bolts about 2 turns. See Fig 2.
10. Disconnect 2 main engine harness connectors at rear of intake manifold. See Fig 1.
11. Disconnect 2 injection wiring harness clips at harness mounting bracket. See Fig 2.
12. Disconnect electrical connectors at all 4 fuel injectors. To remove connector, see 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.
13. Remove 2 injection rail mounting bolts. See Figure.
14. Gently rock and pull fuel rail until fuel injectors just start to clear machined holes in intake manifold.
15. Remove fuel rail (with injectors attached) from intake manifold.
16. If fuel injectors are to be removed, see FUEL RAILS & INJECTORS in REMOVAL, OVERHAUL & INSTALLATION article.