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Home >> Chrysler >> 2009 >> 300 Signature Series >> Repair and Diagnosis >> External Pages >> Different car >> Section 84 (Fuel System) >> Fuel Delivery (Except Diesel) >> Fuel Rail >> Removal >> 2.4L Turbo

2.4L Turbo

WARNING: This page is about a different car, the 2006 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
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.
Fig 1: Throttle Body Connections - 2.4L Turbo
GC0021630Courtesy of DAIMLERCHRYSLER CORP.
1 - Purge Hose
2 - Electrical Connections
3 - Inlet Hose
  1. Release the fuel system pressure. (Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE) .
  2. Disconnect the negative battery cable.
  3. Disconnect the throttle body inlet hose (3) and remove from throttle body.
  4. Disconnect the purge hose from the throttle body (1).
  5. Unlock and disconnect the electrical connection at the throttle body (2).
    Fig 2: Throttle Control Shield - 2.4L Turbo
    GC0021640Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove the throttle control shield.
    Fig 3: MAP Sensor - 2.4L Turbo
    GC0021629Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove the throttle and speed control cables from the throttle body.
  8. Remove the cables from the throttle body bracket.
  9. Unlock and disconnect the MAP sensor electrical connector.
    Fig 4: Vacuum Lines - 2.4L Turbo
    GC0021639Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove the vacuum lines from the rear of the intake manifold.
    Fig 5: Lower Intake Manifold - 2.4L Turbo
    GC0021636Courtesy of DAIMLERCHRYSLER CORP.
  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 DAIMLERCHRYSLER CORP.
  14. Drain the Coolant system (Refer to COOLING - STANDARD PROCEDURE) .
  15. Remove the upper radiator hose clamp.
    Fig 7: Small Hoses At Housing - 2.4L Turbo
    GC0021634Courtesy of DAIMLERCHRYSLER CORP.
  16. Remove the 2 small hoses from the thermostat housing.
    Fig 8: Thermostat Housing - 2.4L Turbo
    GC0021635Courtesy of DAIMLERCHRYSLER CORP.
  17. Remove the 2 bolts from the thermostat housing and rotate the assembly up and out of the way.
    Fig 9: Hose And Housing Rotated - 2.4L Turbo
    GC0021632Courtesy of DAIMLERCHRYSLER CORP.
  18. Rotate upper radiator hose up and out of the way.
    Fig 10: Fuel Line Connection - 2.4L Turbo
    GC0021637Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Wrap shop towels around hose to catch any gasoline spillage.
  19. Disconnect the fuel line from the fuel rail. Refer to the QUICK CONNECT FITTING .
    Fig 11: Fuel Rail - 2.4L Turbo
    GC0021631Courtesy of DAIMLERCHRYSLER CORP.
  20. Unlock and disconnect the electrical connectors from the fuel injectors.
  21. Remove the wiring harness from the fuel rail.
  22. Remove the 2 bolts from the fuel rail.
    Fig 12: Fuel Rail & Injectors - 2.4L Turbo
    GC0021638Courtesy of DAIMLERCHRYSLER CORP.
  23. Remove the fuel rail and injectors from the intake manifold.
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