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Removal And Installation: 2.4L

REMOVAL 

WARNING:

Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.

  1. Perform the fuel system pressure release procedure

    Refer to FUEL DELIVERY, GAS, STANDARD PROCEDURE .

  2. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
  3. Remove the engine cover and clean air hose. Refer to HOSE, CLEAN AIR, REMOVAL AND INSTALLATION .
    GC0169971Courtesy of CHRYSLER GROUP, LLC
  4. Disconnect the purge vapor line quick-connect fitting (2) from the purge solenoid.
    NOTE:

    Wrap shop towels around the fuel hose to catch any gasoline spillage.

  5. Disconnect the fuel line quick-connect fitting (1) from the fuel rail.
    GC0169994Courtesy of CHRYSLER GROUP, LLC
  6. Cut the injector silencer pad at the score line (1) and remove the injector silencer pad.
    GC0169941Courtesy of CHRYSLER GROUP, LLC
  7. Disengage the purge solenoid (1) from its fuel rail mount.
  8. Unlock and disconnect the four Variable Valve Actuation Assembly (VVAA) solenoid wire harness connectors (3).
  9. Unlock and disconnect the four fuel injector wire harness connectors (4).
  10. Remove the three wire harness tray retainers (2) from the cylinder head cover and reposition the wire harness and purge solenoid.
    GC0156429Courtesy of CHRYSLER GROUP, LLC
  11. Remove the bolts (3) and the fuel rail (2).
    GC0082493Courtesy of CHRYSLER GROUP, LLC
  12. If necessary, remove the fuel injectors from the fuel rail.

INSTALLATION 

GC0082493Courtesy of CHRYSLER GROUP, LLC
  1. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
  2. If necessary, install the fuel injectors into the fuel rail using NEW  O-ring seals. Refer to INJECTOR(S), FUEL, REMOVAL AND INSTALLATION .
    GC0156429Courtesy of CHRYSLER GROUP, LLC
  3. Install the fuel rail (2) with bolts (3) tightened to the proper torque specification. Refer to FUEL DELIVERY, GAS, TECHNICAL SPECIFICATIONS .
    GC0169941Courtesy of CHRYSLER GROUP, LLC
  4. Position the wire harness tray onto the cylinder head cover and install the three wire harness tray retainers (2).
  5. Connect and lock the four fuel injector wire harness connectors (4).
  6. Connect and lock the four Variable Valve Actuation Assembly (VVAA) solenoid wire harness connectors (3).
  7. Install the purge solenoid (1) to its fuel rail mount.
    GC0169971Courtesy of CHRYSLER GROUP, LLC
  8. Install the injector silencer pad (3) over the fuel rail.
  9. Connect fuel line quick-connect fitting (1) to the fuel rail.
  10. Connect the purge vapor line quick-connect fitting (2) to the purge solenoid.
  11. Install the clean air hose and engine cover. Refer to HOSE, CLEAN AIR, REMOVAL AND INSTALLATION .
  12. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector.
  13. Use the Scan Tool Fuel System Test to pressurize the fuel system. Check for leaks.
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