Fuel Rail - Installation

2.4L TURBO





1. Install the fuel injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Install injector into cup of fuel rail.
4. Install retaining clip and check to ensure injector is properly captured.




5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
6. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 22.5 Nm (16.5 ft. lbs.).




7. Install the wiring harness to the fuel rail.
8. Connect and lock the electrical connectors to the fuel injectors.
9. Connect the fuel line to the fuel rail.




10. Rotate the assembly back into place.




11. Install the 2 bolts to the thermostat housing tighten to 12.5 Nm (110 in. lbs.).




12. Move the upper radiator house clamp back into place.




13. Install the 2 small hoses to the thermostat housing.
14. Fill the Coolant system.




15. Install the intake manifold.
16. Install the 2 bolts to the rear of the intake manifold tighten to 28 Nm (250 in. lbs.).
17. Install the 5 bolts to the front of the intake manifold and tighten to 28 Nm (250 in. lbs.).




18. Install the vacuum lines to the rear of the intake manifold.




19. Connect and lock the MAP sensor electrical connector.




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.




23. Connect and lock the electrical connections at the throttle body.
24. Connect the purge hose to the throttle body.
25. Connect the throttle body inlet hose to the throttle body and tighten clamps to 3 Nm ±1 (25 in. lbs. ±5) torque.
26. Connect the negative battery cable.
27. Use the San Tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.