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INSTALLATION INSTALLATION - 2.0, 2.4L (1) Install the fuel injectors to the fuel rail. O-ring on the nozzle end of each injector. (3) Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten (4) Attach electrical connectors to fuel injectors. Quick Connect Fittings in the Fuel Delivery section (6) Install Intake Manifold, refer to the Engine section. (7) Install the engine cover or throttle control shield if equipped. (8) Install the negative battery cable. temperature sensor and makeup air hose. Tighten air INSTALLATION - 1.6L (1) Apply a light coating of clean engine oil to the upper O-ring. (2) Install injector in cup on fuel rail. O-ring on the nozzle end of each injector. (5) Insert fuel injector nozzles into openings in lower intake manifold (Fig. 19). Seat the injectors in (6) Attach electrical connectors to fuel injectors (Fig. 17), refer to the fuel injector connector section (7) Connect fuel supply tube to fuel rail (Fig. 18). Refer to Quick Connect Fittings in the Fuel Delivery (8) Install the wiring harness to the fuel rail brackets. (9) Connect the negative battery cable. to pressurize the fuel system. Check for leaks. (11) Install air cleaner assembly cover. INSTALLATION - 2.4L TURBO (1) Apply a light coating of clean engine oil to the upper O-ring. (2) Install injector in cup on fuel rail. 25). (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 (Fig. 24). Tighten fuel rail bolts to 22.5 ±3 N·m (200 ±30 in. (8) Install the wiring harness to the fuel rail (Fig. 24). (9) Connect and lock the electrical connectors to the fuel injectors. (10) Connect the fuel line to the fuel rail (Fig. 23). Refer to Quick Connect Fittings in the Fuel Delivery (11) Rotate the assembly back into place and install the 2 bolts to the thermostat housing tighten (12) Move the upper radiator house clamp back into place (Fig. 19). (13) Install the 2 small hoses to the thermostat housing (Fig. 20). (14) Fill the Coolant system, refer to the Cooling section for more information. (15) Install the intake manifold, refer to the Engine section. (16) Install the 2 bolts to the rear of the intake manifold (Fig. 17) tighten to 28 N·m (250 in. lbs.). (17) Install the 5 bolts to the front of the intake manifold and tighten to 28 N·m (250 in. lbs.). (18) Install the vacuum lines to the rear of the intake manifold (Fig. 17). (19) Connect and lock the MAP sensor electrical connector (Fig. 16). (20) Install the cables to the throttle body bracket. the throttle body. (22) Install the throttle control shield (Fig. 15). the throttle body (Fig. 14). (24) Connect the purge hose to the throttle body (Fig. 14). (25) Connect the throttle body inlet hose to the throttle body (Fig. 14) and tighten clamps to 3 N·m (26) Connect the negative battery cable. to pressurize the fuel system. Check for leaks. FUEL PUMP RELAY DESCRIPTION The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay OPERATION The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Cen- 14 - 36 FUEL INJECTION PT FUEL INJECTOR (Continued) |