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Home >> Chrysler >> 2009 >> PT Cruiser Limited >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System >> Fuel Injection, 2.4L Gas >> INJECTOR(S), Fuel >> Installation >> 2.4L Turbo

2.4L Turbo

Fig 1: FUEL RAIL AND INJECTORS
GC0115125Courtesy 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
    GC0115124Courtesy 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 N.m (16.5 ft. lbs.).
    Fig 3: FUEL LINE CONNECTION
    GC0115123Courtesy 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 Fuel System/Fuel Delivery/FITTING, Quick Connect - Standard Procedure .
    Fig 4: HOSE AND HOUSING ROTATED
    GC0115122Courtesy of CHRYSLER LLC
  11. Rotate the assembly back into place.
    Fig 5: THERMOSTAT HOUSING
    GC0115121Courtesy 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
    GC0115119Courtesy of CHRYSLER LLC
  13. Move the upper radiator house clamp back into place.
    Fig 7: SMALL HOSES AT HOUSING
    GC0115120Courtesy 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
    GC0115118Courtesy of CHRYSLER LLC
  16. Install the intake manifold, refer to the appropriate Engine information.
    Fig 9: VACUUM LINES
    GC0115117Courtesy 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: MAP SENSOR
    GC0115116Courtesy of CHRYSLER LLC
  20. Connect and lock the MAP sensor electrical connector.
    Fig 11: THROTTLE CONTROL SHIELD
    GC0115115Courtesy 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
    GC0115114Courtesy 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 (25 in. lbs.).
  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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