OEM 2005 Chrysler PT Cruiser Fuel Rail

2005 Chrysler PT Cruiser Fuel Rail Parts and Q&A

• Q: How to Service a Fuel Rail on 2005 Chrysler PT Cruiser?

  A: First, let the fuel system pressure out and ensure you work in an open area free from flame and spark. Take off the air cleaner lid, disconnect the inlet temperature sensor from the air cleaner and take off the negative battery cable. If your vehicle comes with one, remove the engine cover or throttle control shield. With shop towels around the hose, collect any escaped gasoline. After that, remove the fuel delivery tube from the fuel rail. Take out the intake manifold and unplug the connections to the fuel injectors. Start by removing the bolts that connect the fuel rail, remove the fuel rail and injectors and finally remove the injectors from the rail. Also for the 2.4L Turbo, release the air pressure, separate the negative battery cable, unlink the throttle body inlet hose, purge hose, connection and control shield. Release the two cables attached to the throttle body and bracket, press the MAP sensor connector in to release it and unhook both vacuum lines from the rear of the intake manifold. First, unbolt the intake manifold at both the front and back and now cover the lower openings with your blocking materials. Coolant must be drained, the upper radiator hose clamp loosened, the thin pipes removed from the thermostat housing and the housing itself turned out of the way. Take the fuel line off the fuel rail, unlock the electrical connectors connecting the fuel injectors, take out the wiring harness connected to the fuel rail and get rid of the fuel rail and injectors from the intake manifold. When installing, place the injectors into the fuel rail, cover the O-ring on each injector's nozzle with clean engine oil, push the nozzles into the intake manifold and secure the fuel rail bolts at 22.5 ± 3 Nm (200 ± 30 in. lbs.). After that, reconnect the wires from the fuel injectors, join the fuel supply tube to the fuel rail and secure the intake manifold. Replace the engine cover or throttle control shield, hook up the negative battery cable, put the lid on the air cleaner, as well as the inlet air temperature sensor and makeup air hose, leaving their clamps tightened at 3 ± 1 Nm (25 ± 5 in. lbs.). Place the fuel injectors into the fuel rail, smear engine oil around the injector O-rings, attach the injectors to the intake manifold, secure the fuel rail with bolts, fit the wiring harness back in and attach the fuel line to the fuel rail. Align and join the thermostat housing again and tighten its bolts to 28 Nm (20 ft. lbs.), set the upper radiator hose clamp in place, attach both little hoses to the thermostat housing, top up the coolant system and attach the intake manifold, again tightening the rear bolts to 28 Nm (20 ft. lbs.) and the front bolts to the same measurement. Re-attach all the vacuum lines, secure the electrical connector on the MAP sensor, put in the throttle body cables and run the throttle control shield, then hook and lock the connections at the throttle body, then join the hoses for the purge and inlet at the throttle body, adjusting clamps to 3 ± 1 Nm (25 ± 5 in. lbs.). Replace the negative battery terminal last and use the DRB scan tool ASD Fuel System Test to pressurize the fuel system and find any leaks.