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Fuel Rail - 2.4L Turbo

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Fuel Rail & Injectors - 2.4L Turbo
GC0021638Courtesy of CHRYSLER LLC
  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 2: Fuel Rail - 2.4L Turbo
    GC0021631Courtesy of CHRYSLER LLC
  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. Tighten fuel rail bolts to 22.5 ±3 N.m (200 ±30 in. lbs.)
    Fig 3: Fuel Line Connection - 2.4L Turbo
    GC0021637Courtesy of CHRYSLER LLC
  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, see STANDARD PROCEDURE .
    Fig 4: Hose & Housing Rotated - 2.4L Turbo
    GC0021632Courtesy of CHRYSLER LLC
  11. Rotate the assembly back into place.
    Fig 5: Thermostat Housing - 2.4L Turbo
    GC0021635Courtesy of CHRYSLER LLC
  12. Install the 2 bolts to the thermostat housing tighten to 12.5 N.m (110 in. lbs.).
    Fig 6: Upper Radiator Hose Clamp - 2.4L Turbo
    GC0021633Courtesy of CHRYSLER LLC
  13. Move the upper radiator house clamp back into place.
    Fig 7: Small Hoses At Housing - 2.4L Turbo
    GC0021634Courtesy of CHRYSLER LLC
  14. Install the 2 small hoses to the thermostat housing.
  15. Fill the Coolant system, refer to COOLING for more information.
    Fig 8: Lower Intake Manifold - 2.4L Turbo
    GC0021636Courtesy of CHRYSLER LLC
  16. Install the intake manifold, refer to MANIFOLD-INTAKE .
    Fig 9: Vacuum Lines - 2.4L Turbo
    GC0021639Courtesy of CHRYSLER LLC
  17. Install the 2 bolts to the rear of the intake manifold tighten to 28 N.m (250 in. lbs.).
  18. Install the 5 bolts to the front of the intake manifold and tighten to 28 N.m (250 in. lbs.).
  19. Install the vacuum lines to the rear of the intake manifold.
    Fig 10: Manifold Absolute Pressure Sensor - 2.4L Turbo
    GC0021629Courtesy of CHRYSLER LLC
  20. Connect and lock the MAP sensor electrical connector.
    Fig 11: Throttle Control Shield - 2.4L Turbo
    GC0021640Courtesy of CHRYSLER LLC
  21. Install the cables to the throttle body bracket.
  22. Install the throttle and speed control cables to the throttle body.
  23. Install the throttle control shield.
    Fig 12: Throttle Body Connections - 2.4L Turbo
    GC0021630Courtesy of CHRYSLER LLC
    1 - Purge Hose
    2 - Electrical Connections
    3 - Inlet Hose
  24. Connect and lock the electrical connections at the throttle body.
  25. Connect the purge hose to the throttle body.
  26. Connect the throttle body inlet hose to the throttle body and tighten clamps to 3 N.m ±1 (25 in. lbs. ±5) torque.
  27. Connect the negative battery cable.
  28. Use the scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
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