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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.
Fig 1: Fuel Rail & Injectors - 2.4L Turbo
GC0021638Courtesy of DAIMLERCHRYSLER CORP.
  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 DAIMLERCHRYSLER CORP.
  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 DAIMLERCHRYSLER CORP.
  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, (Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE) .
    Fig 4: Hose And Housing Rotated - 2.4L Turbo
    GC0021632Courtesy of DAIMLERCHRYSLER CORP.
  11. Rotate the assembly back into place.
    Fig 5: Thermostat Housing - 2.4L Turbo
    GC0021635Courtesy of DAIMLERCHRYSLER CORP.
  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 DAIMLERCHRYSLER CORP.
  13. Move the upper radiator house clamp back into place.
    Fig 7: Small Hoses At Housing - 2.4L Turbo
    GC0021634Courtesy of DAIMLERCHRYSLER CORP.
  14. Install the 2 small hoses to the thermostat housing.
  15. Fill the Coolant system.
    Fig 8: Lower Intake Manifold - 2.4L Turbo
    GC0021636Courtesy of DAIMLERCHRYSLER CORP.
  16. Install the intake manifold.
    Fig 9: Vacuum Lines - 2.4L Turbo
    GC0021639Courtesy of DAIMLERCHRYSLER CORP.
  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: MAP Sensor - 2.4L Turbo
    GC0021629Courtesy of DAIMLERCHRYSLER CORP.
  20. Connect and lock the MAP sensor electrical connector.
    Fig 11: Throttle Control Shield - 2.4L Turbo
    GC0021640Courtesy of DAIMLERCHRYSLER CORP.
  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 DAIMLERCHRYSLER CORP.
    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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