Fuel Injector: Service and Repair
STANDARD PROCEDURE - INJECTOR CONNECTOR REMOVALFig. 14 Fuel Injectors:
Fig. 15 Remove/Install Injector Conneector:
1. Disconnect electrical connectors at the fuel injectors (Fig. 14). To remove connector refer to (Fig. 15). Pull the red colored slider away from injector (1). While pulling the 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, make note of wiring location before removal.
REMOVAL - 2.4L TURBO
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.
1. Release the fuel system pressure. Refer to Fuel System Pressure Release procedure.
2. Disconnect the negative battery cable.
Fig.20 Throttle Body Connections -2.4L Turbo:
3. Disconnect the throttle body inlet hose (Fig. 20) and remove from throttle body.
4. Disconnect the purge hose from the throttle body (Fig. 20).
5. Unlock and disconnect the electrical connection at the throttle body (Fig. 20).
Fig. 21 Throttle Control Shield - 2.4L Turbo:
6. Remove the throttle control shield (Fig. 21).
7. Remove the throttle and speed control cables from the throttle body.
8. Remove the cables from the throttle body bracket.
Fig. 22 Map Sensor - 2.4L Turbo:
9. Unlock and disconnect the MAP sensor electrical connector (Fig. 22).
Fig. 23 Vacuum Lines - 2.4L Turbo:
10. Remove the vacuum lines from the rear of the intake manifold (Fig. 23).
11. Remove the 5 bolts from the front of the intake manifold.
12. Remove the 2 bolts from the rear of the intake manifold.
Fig. 24 Lower Intake Manifold - 2.4L Turbo:
13. Remove the intake manifold. Cover the lower intake manifold openings (Fig. 24).
14. Drain the Coolant system, refer to the Cooling for more information.
Fig. 25 Upper Radiator Hose Clamp - 2.4L Turbo:
15. Move the upper radiator hose clamp (Fig. 25), so that the hose can be rotated up and out of the way.
Fig. 26 Small Hoses At Housing - 2.4L Turbo:
16. Remove the 2 small hoses from the thermostat housing (Fig. 26).
Fig. 27 Thermostat Housing - 2.4L Turbo:
Fig. 28 Hose And Housing Rotated - 2.4L Turbo:
17. Remove the 2 bolts from the thermostat housing (Fig. 27) and rotate the assembly up and out of the way (Fig. 28).
WARNING: WRAP SHOP TOWELS AROUND HOSE TO CATCH ANY GASOLINE SPILLAGE.
Fig. 29 Fuel Line Connection - 2.4L Turbo:
18. Disconnect the fuel line from the fuel rail (Fig. 29). Refer to the Quick-Connect Fittings.
19. Unlock and disconnect the electrical connectors from the fuel injectors.
Fig. 30 Fuel Rail - 2.4L Turbo:
20. Remove the wiring harness from the fuel rail (Fig. 30).
21. Remove the 2 bolts from the fuel rail (Fig. 30).
Fig. 31 Fuel Rail & Injectors - 2.4L Turbo:
22. Remove the fuel rail and injectors from the intake manifold (Fig. 31).
23. Remove the fuel injector from the fuel rail.
INSTALLATION - 2.4L TURBO
1. Apply a light coating of clean engine oil to the upper O-ring.
2. Install injector in cup on fuel rail.
3. Install retaining clip.
4. Install the fuel injectors to the fuel rail (Fig. 31).
5. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
6. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
7. Install the 2 bolts to the fuel rail (Fig. 30). Tighten fuel rail bolts to 22.5 ± 3 Nm (200 ± 30 in. lbs.)
8. Install the wiring harness to the fuel rail.
9. Connect and lock the electrical connectors to the fuel injectors.
10. Connect the fuel line to the fuel rail (Fig. 29). Refer to Quick Connect Fittings in the Fuel Delivery.
11. Rotate the assembly back into place and install the 2 bolts to the thermostat housing and tighten to 28 Nm (20 ft. lbs.).
12. Move the upper radiator house clamp back into place (Fig. 25).
13. Install the 2 small hoses to the thermostat housing (Fig. 26).
14. Fill the Coolant system, refer to the Cooling for more information.
15. Install the intake manifold, refer to Engine.
16. Install the 2 bolts to the rear of the intake manifold and tighten to 28 Nm (20 ft. lbs.).
17. Install the 5 bolts to the front of the intake manifold and tighten to 28 Nm (20 ft. lbs.).
18. Install the vacuum lines to the rear of the intake manifold (Fig. 23).
19. Connect and lock the MAP sensor electrical connector (Fig. 22).
20. Install the cables to the throttle body bracket.
21. Install the throttle and speed control cables to the throttle body
22. Install the throttle control shield (Fig. 21).
23. Connect and lock the electrical connections at the throttle body (Fig. 14).
24. Connect the purge hose to the throttle body (Fig. 20).
25. Connect the throttle body inlet hose (Fig. 20) to the throttle body and tighten clamps to 3 ± 1 Nm (25 ± 5 in. lbs.) torque.
26. Connect the negative battery cable.
27. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.