Removal - 2.4L Turbo

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.

Release the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
Disconnect the negative battery cable.
Disconnect the throttle body inlet hose and remove from throttle body.

Fig 1: Disconnecting Throttle Body Connections - Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Disconnect the purge hose from the throttle body.
Unlock and disconnect the electrical connection at the throttle body.
Remove the throttle control shield.

Fig 2: Removing Throttle Control Shield - Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Remove the throttle and speed control cables from the throttle body.
Remove the cables from the throttle body bracket.
Unlock and disconnect the MAP sensor electrical connector.

Fig 3: Locating MAP Sensor - Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Remove the vacuum lines from the rear of the intake manifold.

Fig 4: Removing Vacuum Lines - Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Remove the 5 bolts from the front of the intake manifold.
Remove the 2 bolts from the rear of the intake manifold.
Remove the intake manifold. Cover the lower intake manifold openings.

Fig 5: Removing Lower Intake Manifold - Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Drain the Coolant system, see COOLING SYSTEM MECHANICAL article.
Move the upper radiator hose clamp, so that the hose can be rotated up and out of the way.

Fig 6: Moving Upper Radiator Hose Clamp - Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Remove the 2 small hoses from the thermostat housing.

Fig 7: Removing Small Hoses At Housing - Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Remove the 2 bolts from the thermostat housing and rotate the assembly up and out of the way.

Fig 8: Removing Thermostat Housing - Turbo
Courtesy of DAIMLERCHRYSLER CORP.

Fig 9: Identifying Hose & Housing Rotated - Turbo
Courtesy of DAIMLERCHRYSLER CORP.

NOTE: WRAP SHOP TOWELS AROUND HOSE TO CATCH ANY GASOLINE SPILLAGE.

Fig 10: Disconnecting Fuel Line Connection - Turbo

Courtesy of DAIMLERCHRYSLER CORP.

Disconnect the fuel line from the fuel rail. See QUICK CONNECT FITTING .
Unlock and disconnect the electrical connectors from the fuel injectors.
Remove the wiring harness from the fuel rail.

Fig 11: Removing Bolts & Wiring Harness From Fuel Rail
Courtesy of DAIMLERCHRYSLER CORP.
Remove the 2 bolts from the fuel rail.
Remove the fuel rail and injectors from the intake manifold.

Fig 12: Removing Fuel Rail & Injectors - Turbo
Courtesy of DAIMLERCHRYSLER CORP.
Remove the fuel injector from the fuel rail.