Fuel Rail: Removal: 2.4L

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

1. Remove fuel tank filler tube cap.
2. Perform STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE .
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. A special tool will be necessary for fuel line disconnection. Refer to QUICK CONNECT FITTING .
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 cover.
9. Remove 3 upper intake manifold mounting bolts, but loosen 2 lower bolts about 2 turns
   Fig 1: Identifying Fuel Rail Mounting - 2.4L

   Courtesy of DAIMLERCHRYSLER CORP.
10. Disconnect 2 main engine harness connectors at rear of intake manifold.
    Fig 2: Locating MAP Sensor - 2.4L

    Courtesy of DAIMLERCHRYSLER CORP.
11. Disconnect 2 injection wiring harness clips at harness mounting bracket.
12. Disconnect electrical connectors at all 4 fuel injectors. 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.
    Fig 3: Removing & Installing Injector Connector

    Courtesy of DAIMLERCHRYSLER CORP.
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, refer to FUEL INJECTION .