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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: Throttle Body Connections - 2.4L Turbo
GC0021630Courtesy of CHRYSLER LLC
1 - Purge Hose
2 - Electrical Connections
3 - Inlet Hose
WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.
  1. Release the fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
  2. Disconnect the negative battery cable.
  3. Disconnect the throttle body inlet hose and remove from throttle body.
  4. Disconnect the purge hose from the throttle body.
  5. Unlock and disconnect the electrical connection at the throttle body.
    Fig 2: Throttle Control Shield - 2.4L Turbo
    GC0021640Courtesy of CHRYSLER LLC
  6. Remove the throttle control shield.
  7. Remove the throttle and speed control cables from the throttle body.
  8. Remove the cables from the throttle body bracket.
    Fig 3: Manifold Absolute Pressure Sensor - 2.4L Turbo
    GC0021629Courtesy of CHRYSLER LLC
  9. Unlock and disconnect the MAP sensor electrical connector.
    Fig 4: Vacuum Lines - 2.4L Turbo
    GC0021639Courtesy of CHRYSLER LLC
  10. Remove the vacuum lines from the rear of the intake manifold.
    Fig 5: Lower Intake Manifold - 2.4L Turbo
    GC0021636Courtesy of CHRYSLER LLC
  11. Remove the 5 bolts from the front of the intake manifold.
  12. Remove the 2 bolts from the rear of the intake manifold.
  13. Remove the intake manifold. Cover the lower intake manifold openings.
    Fig 6: Upper Radiator Hose Clamp - 2.4L Turbo
    GC0021633Courtesy of CHRYSLER LLC
  14. Drain the Coolant system, refer to COOLING for more information.
  15. Move the upper radiator hose clamp, so that the hose can be rotated up and out of the way.
    Fig 7: Small Hoses At Housing - 2.4L Turbo
    GC0021634Courtesy of CHRYSLER LLC
  16. Remove the 2 small hoses from the thermostat housing.
    Fig 8: Thermostat Housing - 2.4L Turbo
    GC0021635Courtesy of CHRYSLER LLC
  17. Remove the 2 bolts from the thermostat housing.
    Fig 9: Hose & Housing Rotated - 2.4L Turbo
    GC0021632Courtesy of CHRYSLER LLC
  18. Rotate the assembly up and out of the way.
    Fig 10: Fuel Line Connection - 2.4L Turbo
    GC0021637Courtesy of CHRYSLER LLC
    NOTE: Wrap shop towels around hose to catch any gasoline spillage.
  19. Disconnect the fuel line from the fuel rail. See STANDARD PROCEDURE .
    Fig 11: Fuel Rail - 2.4L Turbo
    GC0021631Courtesy of CHRYSLER LLC
  20. Unlock and disconnect the electrical connectors from the fuel injectors.
  21. Remove the wiring harness from the fuel rail.
    Fig 12: Fuel Rail & Injectors - 2.4L Turbo
    GC0021638Courtesy of CHRYSLER LLC
  22. Remove the 2 bolts from the fuel rail.
  23. Remove the fuel rail and injectors from the intake manifold.
  24. Remove the fuel injector from the fuel rail.
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