Upper Intake Manifold: Turbo

Fig 1: IAT Sensor - 2.4L Turbo

Courtesy of DAIMLERCHRYSLER CORP.

1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY

2 - IAT SENSOR

3 - TIP HOSE

NOTE: This engine could be equipped with an aluminum Intake manifold or a plastic intake manifold.

Disconnect the throttle inlet pressure (TIP) hose (3). See Fig 1.

Fig 2: Charge Air Cooler Hoses

Courtesy of DAIMLERCHRYSLER CORP.

1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY

2 - CHARGE AIR COOLER

3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER

Disconnect charge air cooler hose at throttle body (1). See Fig 2.
Disconnect idle air control (IAC) motor and throttle position sensor connectors.

Fig 3: MAP Sensor - 2.4L Turbo
Courtesy of DAIMLERCHRYSLER CORP.

1 - MAP SENSOR
Disconnect the MAP sensor connector (1). See Fig 3.

Fig 4: Throttle Control Shield 2.4L Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Remove the throttle control shield. See Fig 4.

Fig 5: Throttle Cables - 2.4L Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Remove the throttle cable from the throttle body lever. See Fig 5.
If equipped with speed control, remove speed control cable from the throttle lever by sliding clasp out hole used for throttle cable.

Fig 6: Throttle Cable Bracket - 2.4L Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Remove the 2 screws for the throttle cable bracket.
Reposition throttle cable bracket. See Fig 6.

Remove intake manifold cover.

NOTE: To remove intake manifold cover, start with clips near throttle body.

Fig 7: Vacuum Hoses - 2.4L Turbo

Courtesy of DAIMLERCHRYSLER CORP.

1 - PURGE SOLENOID HOSE

2 - BRAKE BOOSTER HOSE

3 - PCV HOSE

Disconnect brake booster hose (3) and PCV hose (3) from intake manifold. See Fig 7.
Disconnect purge solenoid hose (1) from throttle body. See Fig 7.

Fig 8: Support Bracket
Courtesy of DAIMLERCHRYSLER CORP.

1 - FASTENERS

2 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
Remove upper intake manifold support bracket (2). See Fig 8.
Remove upper intake manifold fasteners (1).
Remove upper intake manifold.

Fig 9: Covering Lower Intake Manifold Openings
Courtesy of DAIMLERCHRYSLER CORP.

1 - INTAKE MANIFOLD MUST BE COVERED DURING SERVICE
If further service is required, cover the lower intake manifold openings (1) to prevent foreign materials from entering the engine.