2002 CHRYSLER CARAVAN coolant temperature

Component Page
C322 (Memory)..................... 8W-80-39
C322 (Memory)..................... 8W-80-39
C324 (Manual Sliding Door)........... 8W-80-39
C324 (Manual Sliding Door)........... 8W-80-40
C325 (Manual Sliding Door)........... 8W-80-40
C325 (Manual Sliding Door)........... 8W-80-40
C326............................. 8W-80-40
C326............................. 8W-80-40
C327............................. 8W-80-40
C327............................. 8W-80-41
C329 (Diesel)....................... 8W-80-41
C329 (Diesel)....................... 8W-80-41
C330 (Diesel)....................... 8W-80-41
C330 (Diesel)....................... 8W-80-41
C331 (Diesel)....................... 8W-80-42
C331 (Diesel)....................... 8W-80-42
C332 (ATC)........................ 8W-80-42
C332 (ATC)........................ 8W-80-42
Cabin Heater Assist C1 (Diesel)........ 8W-80-42
Cabin Heater Assist C2 (Diesel)........ 8W-80-43
Camshaft Position Sensor (Diesel)...... 8W-80-43
Camshaft Position Sensor (Gas)........ 8W-80-43
CD Changer....................... 8W-80-43
Center Dome Lamp (Base/High Line).... 8W-80-43
Center High Mounted Stop Lamp....... 8W-80-44
Clockspring C1..................... 8W-80-44
Clockspring C2..................... 8W-80-44
Clockspring C3..................... 8W-80-44
Clockspring C4..................... 8W-80-44
Clockspring C5..................... 8W-80-45
Clutch Pedal Interlock Switch (MTX).... 8W-80-45
Clutch Pedal Interlock Switch Jumper
(ATX) .......................... 8W-80-45
Clutch Pedal Upstop Switch (Diesel)..... 8W-80-45
Controller Antilock Brake............. 8W-80-46
Crank Case Ventilation Heater (Diesel) . . 8W-80-46
Crankshaft Position Sensor (Diesel)..... 8W-80-46
Crankshaft Position Sensor (Gas)....... 8W-80-47
Data Link Connector................. 8W-80-47
Diagnostic Junction Port.............. 8W-80-47
Dosing Pump (Diesel)................ 8W-80-48
Driver Airbag C1.................... 8W-80-48
Driver Airbag C2.................... 8W-80-48
Driver Blend Door Actuator (ATC)...... 8W-80-48
Driver Blend Door Actuator (MTC)...... 8W-80-48
Driver Door Courtesy Lamp........... 8W-80-49
Driver Door Lock Switch.............. 8W-80-49
Driver Heated Seat Back............. 8W-80-49
Driver Heated Seat Cushion........... 8W-80-49
Driver Heated Seat Module C1......... 8W-80-49
Driver Heated Seat Module C2......... 8W-80-50
Driver Heated Seat Module C3......... 8W-80-50
Driver Power Seat Front Riser Motor.... 8W-80-50Component Page
Driver Power Seat Front Riser
Position Sensor................... 8W-80-50
Driver Power Seat Horizontal Motor..... 8W-80-50
Driver Power Seat Horizontal
Position Sensor................... 8W-80-51
Driver Power Seat Rear Riser Motor.... 8W-80-51
Driver Power Seat Rear Riser
Position Sensor................... 8W-80-51
Driver Power Seat Recliner Motor...... 8W-80-51
Driver Power Seat Recliner
Position Sensor................... 8W-80-51
Driver Power Seat Switch............. 8W-80-52
Driver Power Window Motor........... 8W-80-52
Driver Power Window Switch
(Except Lowline).................. 8W-80-52
Driver Power Window Switch (Lowline) . . 8W-80-53
Driver Power Window Switch (RHD).... 8W-80-53
Driver Seat Belt Switch.............. 8W-80-53
Driver Seat Belt Tensioner............ 8W-80-53
EGR Solenoid (Diesel)................ 8W-80-54
EGR Solenoid (Gas)................. 8W-80-54
Electric Wiper De-Icer C1............. 8W-80-54
Electric Wiper De-Icer C2............. 8W-80-54
Engine Control Module C1 (Diesel)...... 8W-80-55
Engine Control Module C2 (Diesel)...... 8W-80-57
Engine Coolant Temp Sensor (Diesel).... 8W-80-57
Engine Coolant Temp Sensor (Gas)...... 8W-80-58
Engine Oil Pressure Sensor (Diesel)..... 8W-80-58
Engine Oil Pressure Switch (Gas)....... 8W-80-58
Engine Oil Temperature Sensor (Diesel) . . 8W-80-58
EVAP/Purge Solenoid (Gas)............ 8W-80-58
Evaporator Temperature Sensor........ 8W-80-59
Floor Console Lamp................. 8W-80-59
Floor Console Power Outlet........... 8W-80-59
Front Blower Module C1 (ATC)......... 8W-80-59
Front Blower Module C2 (ATC)......... 8W-80-59
Front Cigar Lighter................. 8W-80-60
Front Reading Lamps/Switch.......... 8W-80-60
Front Washer Pump Motor............ 8W-80-60
Fuel Heater (Diesel)................. 8W-80-60
Fuel Injector No. 1 (2.4L/3.3L/3.8L)..... 8W-80-60
Fuel Injector No. 1 (Diesel)............ 8W-80-61
Fuel Injector No. 2 (2.4L/3.3L/3.8L)..... 8W-80-61
Fuel Injector No. 2 (Diesel)............ 8W-80-61
Fuel Injector No. 3 (2.4L/3.3L/3.8L)..... 8W-80-61
Fuel Injector No. 3 (Diesel)............ 8W-80-61
Fuel Injector No. 4 (2.4L/3.3L/3.8L)..... 8W-80-62
Fuel Injector No. 4 (Diesel)............ 8W-80-62
Fuel Injector No. 5 (3.3L/3.8L)......... 8W-80-62
Fuel Injector No. 6 (3.3L/3.8L)......... 8W-80-62
Fuel Pressure Sensor (Diesel).......... 8W-80-62
Fuel Pressure Solenoid (Diesel)......... 8W-80-63
Fuel Pump Module.................. 8W-80-63
Generator......................... 8W-80-63
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTSRS
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ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
CAV CIRCUIT FUNCTION
1 Z130 14BK/BR GROUND
2 Z131 14BK/DG GROUND
3 K20 14BR/GY GENERATOR FIELD CONTROL
4 K342 14BR/WT ECM/PCM RELAY OUTPUT
5 K342 14BR/WT ECM/PCM RELAY OUTPUT
6- -
7 D25 20WT/VT PCI BUS
8 K944 20BK/GY CAMSHAFT POSITION SENSOR SHIELD GROUND
9 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL
10 - -
11 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
12 K55 20DB/OR MASS AIR FLOW SENSOR SIGNAL
13 K78 20GY FUEL PRESSURE SENSOR SIGNAL
14 - -
15 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL
16 K80 20DB/TN FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
19 N1 20DB/OR FUEL HEATER RELAY OUTPUT
20 Z138 20BK/OR GROUND
21 K900 20DB/DG SENSOR GROUND
22 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
23 F851 20LB/PK SENSOR REFERENCE VOLTAGE B
24 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
25 - -
26 - -
27 - -
28 - -
29 - -
30 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
31 F853 20LG/PK WATER IN FUEL SENSOR SIGNAL
32 K25 20BR/TN BATTERY TEMPERATURE SENSOR SIGNAL
33 - -
34 K167 20BR/YL ACCELERATOR PEDAL POSITION SENSOR GROUND
35 K853 20DB/BR ACCELERATOR PEDAL POSITION SENSOR 5 VOLT
SUPPLY
36 C18 20LB/BR A/C PRESSURE SENSOR SIGNAL
37 K89 20DB/WT ENGINE OIL TEMPERATURE SENSOR SIGNAL
38 V37 20VT/TN SPEED CONTROL SWITCH SIGNAL
39 - -
40 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
41 K21 20DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
42 Z122 18WT GROUND (DRAIN)
43 K24 20BR/LB CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
44 - -
45 - -
46 - -
47 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT
48 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL
49 T751 20YL FUSED IGNITION SWITCH OUTPUT (START)
50 F855 20PK/YL SENSOR REFERENCE VOLTAGE A
51 - -
52 K121 20DB BOOST PRESSURE SENSOR GROUND
53 - -
54 K957 20BK/OR MASS AIR FLOW SENSOR GROUND
RS8W-80 CONNECTOR PIN-OUTS8W-80-55
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ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY
CAV CIRCUIT FUNCTION
82 - -
83 - -
84 - -
85 - -
86 T753 20DG/YL FUSED IGNITION SWITCH OUTPUT (START)
87 - -
88 K35 20GY/YL EGR SOLENOID CONTROL
89 K35 20GY/YL EGR SOLENOID CONTROL
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
97 - -
98 - -
99 - -
100 - -
101 - -
102 - -
103 - -
104 - -
105 - -
106 - -
107 - -
108 - -
109 - -
110 - -
111 - -
112 K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE
113 - -
114 - -
115 K14 14LB/BR FUEL INJECTOR NO. 4 CONTROL
116 K111 14DB/LB COMMON INJECTOR DRIVER
117 - -
118 K11 14WT/DB FUEL INJECTOR NO. 1 CONTROL
119 K12 14TN FUEL INJECTOR NO. 2 CONTROL
120 K13 14BR/LB FUEL INJECTOR NO. 3 CONTROL
121 - -
ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAY
CAV CIRCUIT FUNCTION
1 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
2 K900 20DB/DG SENSOR GROUND
RS8W-80 CONNECTOR PIN-OUTS8W-80-57
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ENGINE COOLANT TEMP SENSOR (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K900 18DB/DG SENSOR GROUND
2 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 F855 20PK/YL SENSOR REFERENCE VOLTAGE A
2 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
3 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
ENGINE OIL PRESSURE SWITCH (GAS) - LT. GREEN 2 WAY
CAV CIRCUIT FUNCTION
1 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE
2- -
ENGINE OIL TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K89 20DB/WT ENGINE OIL TEMPERATURE SENSOR SIGNAL
2 K900 20DB/OR SENSOR GROUND
EVAP/PURGE SOLENOID (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K52 18DB/WT EVAPORATIVE EMISSION SOLENOID CONTROL
2 K70 18DB/BR EVAPORATIVE EMISSION SOLENOID SENSE
8W - 80 - 58 8W-80 CONNECTOR PIN-OUTSRS
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POWER WINDOW SWITCH (LOWLINE) - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
2 Z421 12BK/BR GROUND
3 Z421 12BK/BR GROUND
4- -
5 Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER DOWN
6 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
7 Z421 20BK/BR GROUND
8 Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER UP
POWERTRAIN CONTROL MODULE C1 (GAS) - GRAY/BLACK 40-WAY
CAV CIRCUIT FUNCTION
1- -
2 K18 16DB/OR (3.3L/3.8L) IGNITION COIL NO. 3 DRIVER
3 K17 16DB/TN IGNITION COIL NO. 2 DRIVER
4- -
5 V32 18VT/YL SPEED CONTROL ON/OFF SWITCH SENSE
6 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT
7 K13 16BR/LB FUEL INJECTOR NO. 3 DRIVER
8 K20 18BR/GY GENERATOR FIELD CONTROL
9- -
10 Z130 18BK/BR GROUND
11 K19 16DB/DG IGNITION COIL NO. 1 DRIVER
12 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE
13 K11 16BR/YL FUEL INJECTOR NO. 1 DRIVER
14 K58 16BR/VT (3.3L/3.8L) FUEL INJECTOR NO. 6 DRIVER
15 K38 16BR/OR (3.3L/3.8L) FUEL INJECTOR NO. 5 DRIVER
16 K14 16BR/TN FUEL INJECTOR NO. 4 DRIVER
17 K12 16BR/DB FUEL INJECTOR NO. 2 DRIVER
18 K99 18BR/LG OXYGEN SENSOR 1/1 HEATER CONTROL
19 - -
20 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
21 - -
22 - -
23 - -
24 - -
25 K42 18DB/YL (EXCEPT 3.3L/3.8L
BUILT-UP-EXPORT)KNOCK SENSOR SIGNAL
26 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
27 K902 18BR/DG OXYGEN SENSOR GROUND
28 - -
29 - -
30 K41 18DB/LB OXYGEN SENSOR 1/1 SIGNAL
31 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL
32 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL
33 K44 18DB/GY CAMSHAFT POSITION SENSOR SIGNAL
34 - -
35 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL
36 K1 18VT/BR MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
37 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
38 - -
39 - -
40 K35 18DB/VT EGR SOLENOID CONTROL
8W - 80 - 94 8W-80 CONNECTOR PIN-OUTSRS
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Driver Power Seat Front Riser
MotorRD At Seat N/S
Driver Power Seat Horizontal Motor BK At Seat N/S
Driver Power Seat Rear Riser
MotorRD At Seat N/S
Driver Power Seat Recliner Motor GN At Seat N/S
Driver Power Seat Switch GN At Switch N/S
Driver Power Window Motor RD At Motor N/S
Driver Power Window Switch GN At Switch N/S
Driver Power Window Switch
(RHD)NAT At Switch N/S
Driver Seatbelt Switch WT At Switch on Seat Harness N/S
Driver Seatbelt Tensioner On Seat Harness N/S
EGR Solenoid (Diesel) BK Above Transmission
Right Side of EngineN/S
EGR Solenoid GY Above Transmission
Right Side of Engine9, 10, 11, 13
Electric Wiper De-Icer-C1 WT Right Side Instrument Panel 15, 1923
Electric Wiper De-Icer-C2 WT Left Side Instrument Panel 15, 16, 22
Engine Control Module C1 (Diesel) BK Right Side of Engine 11
Engine Control Module C2 (Diesel) BK Right Side of Engine 11
Engine Coolant Temperature
Sensor (Gas)BK On Cylinder Block N/S
Engine Coolant Temperature
Sensor (Diesel)BL On Cylinder Block 11
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 12
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 9
Engine Oil Temperature Sensor
(Diesel)BK Rear of Engine 12
EVAP/Purge Solenoid BK Right Motor Mount 9, 13
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 15, 18, 20
Front Reading Lamps/Switch BK At Switch N/S
Front Washer Pump Motor BK Right Fender Well 3
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 BK At Fuel Injector N/S
Fuel Injector No.1 (Diesel) BK At Fuel Injector 11
Fuel Injector No.2 BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 11
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.(4) Remove the Auto Shutdown (ASD) relay from
the PDC.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gauge adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer (Special Tool CH7059) with cable adap-
tors to the DRBIIIt. For Special Tool identification,
(Refer to 9 - ENGINE - SPECIAL TOOLS).
(7) Crank engine until maximum pressure is
reached on gauge. Record this pressure as #1 cylin-
der pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE PRESSURE CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the pressure cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
RSENGINE 2.4L9-9
ENGINE 2.4L (Continued)
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(12) Remove engine oil dipstick from tube.
(13) Remove upper intake manifold bolts (Fig.
108). Remove upper intake manifold.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
(1) Clean manifold sealing surfaces.
(2) Apply a 1.5 mm (0.060 in.) bead MopartGas-
ket Maker to the perimeter of the lower intake man-
ifold runner openings.
(3) Install upper intake manifold and tighten fas-
teners to 28 N´m (250 in. lbs.) in sequence shown in
(Fig. 108). Repeat this procedures until all fasteners
are at specified torque.
(4) Install engine oil dipstick.
(5) Install upper bolt in intake manifold to front
support bracket (Fig. 107). Torque to 28 N´m (250 in.
lbs.).
(6) Install EGR tube. (Refer to 25 - EMISSIONS
CONTROL/EXHAUST GAS RECIRCULATION/
TUBE - INSTALLATION)
(7) Install throttle cables in bracket.
(8) Connect throttle, speed control, (if equipped),
transaxle control (31TH equipped only) cables to
throttle lever.
(9) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(10) Connect vacuum lines for purge solenoid and
PCV valve.(11) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(12) Install air cleaner upper housing and air
intake tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor (Fig. 104).
(14) Connect negative cable to battery.
INTAKE MANIFOLD - LOWER
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
CAUTION: Cover intake manifold openings to pre-
vent foreign material from entering engine.
(3) Disconnect fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(4) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(5) Remove heater supply and radiator upper
hoses at intake manifold.
(6) Disconnect coolant temperature sensor/fuel
injector wire harness connector.
(7) Remove lower intake manifold support bracket
upper bolts (Fig. 109).
(8) Loosen the lower intake manfold support
bracket lower bolt (Fig. 109).
(9) Disconnect fuel injector harness.
(10) Remove the bolts attaching the power steering
reservoir to manifold. Set reservoir aside.Do not
disconnect line from reservoir.
(11) Remove lower intake manifold fasteners (Fig.
110). Remove the manifold from engine.
(12) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION)
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
If the following items were removed, install and
torque to specifications:
²Fuel rail bolts - 22 N´m (200 in. lbs.)
Fig. 108 Upper Intake Manifold Tightening Sequence
- 2.4L
RSENGINE 2.4L9-61
INTAKE MANIFOLD - UPPER (Continued)
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