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2.4L Turbo

  1. Install the fuel injectors to the fuel rail. See Figure.
  2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
  3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
  4. Install the 2 bolts to the fuel rail. See Figure. Tighten fuel rail bolts to 22.5 +/-3 N.m (200 +/-30 in. lbs.)
  5. Install the wiring harness to the fuel rail. See Figure.
  6. Connect and lock the electrical connectors to the fuel injectors.
  7. Connect the fuel line to the fuel rail. See Figure. See QUICK CONNECT FITTING .
  8. Rotate the assembly back into place and install the 2 bolts to the thermostat housing tighten to 12.5 N.m (110 in. lbs.).
  9. Move the upper radiator house clamp back into place. See Figure.
  10. Install the 2 small hoses to the thermostat housing. See Figure.
  11. Fill the Coolant system, refer to COOLING for more information.
  12. Install the intake manifold, refer to INTAKE MANIFOLD .
  13. Install the 2 bolts to the rear of the intake manifold tighten to 28 N.m (250 in. lbs.). See Figure.
  14. Install the 5 bolts to the front of the intake manifold and tighten to 28 N.m (250 in. lbs.).
  15. Install the vacuum lines to the rear of the intake manifold. See Figure.
  16. Connect and lock the MAP sensor electrical connector. See Figure.
  17. Install the cables to the throttle body bracket.
  18. Install the throttle and speed control cables to the throttle body.
  19. Install the throttle control shield. See Figure.
  20. Connect and lock the electrical connections at the throttle body. See Figure.
  21. Connect the purge hose to the throttle body. See Figure.
  22. Connect the throttle body inlet hose to the throttle body and tighten clamps to 3 N.m +/-1 (25 in. lbs. +/-5) torque. See Figure.
  23. Connect the negative battery cable.
  24. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
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