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JR
INTAKE MANIFOLD (Continued)
Fig. 96 Fuel Rail Support Bracket
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
(1) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
(2) Inspect manifold for gasket surface damage or
warpage. Replace manifold if necessary.
INSTALLATION
(1) Install new intake manifold and gasket. Grad-
ually tighten fasteners to 28 N·m (250 in. lbs.) in
sequence shown in (Fig. 97).
(2) Install coolant outlet connector (Refer to 7 -
COOLING/ENGINE/COOLANT OUTLET HOUSING
- INSTALLATION).
(3) Install fuel rail.
(4) Install fuel rail support bracket (Fig. 96).
(5) Connect previously disconnected electrical con-
nectors.
(6) Install fastener holding fuel rail bracket to side
of cylinder head.
(7) Inspect quick connect fittings for damage,
replace if necessary. Connect fuel supply hose to fuel
ENGINE 2.4L DOHC
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(8) Connect vacuum hoses to intake manifold.
(9) Install engine oil dipstick and tube.
(10) Install EGR tube (Refer to 25 - EMISSIONS
CONTROL/EXHAUST
TUBE - INSTALLATION).
(11) Install throttle and speed control cables to
bracket. Connect cables to the throttle lever.
(12) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(13) Connect negative battery cable.
(14) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
Fig. 97 Intake Manifold Tightening Sequence
9 - 129
GAS
RECIRCULATION/
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