Stratus L4-2.4L DOHC (1995)
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Cracked or distorted manifold.
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Torn or missing 0-rings at the mating surface of the manifold Fig. 9.
INSTALLATION
1. Install new intake manifold gasket and manifold onto cylinder head and tighten fasteners to 11.9 Nm (105 in lb) in sequence shown in Figs. 6 and
8.
2. Remove covering from fuel injector holes and insure the holes are clean. Install fuel rail assembly to intake manifold. Tighten screws to 23 Nm
(200 in lb).
3. Connect PCV and brake booster hoses Fig. 4.
4. Inspect quick connect fittings for damage, replace if necessary Refer to Fuel System, for procedure. Lube tube with clean 30w engine oil.
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Connect fuel supply hose to fuel rail assembly.
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Check connection by pulling on connector to insure it locked into position.
5. Install throttle body tighten fastener to 22 Nm (200 in lb).
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Install transmission to throttle body support bracket and tighten to 11.9 Nm (105 in lb) at the throttle body first.
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Next tighten the bracket at the transmission.
6. Connect Manifold Absolute Pressure (MAP) and intake air temperature sensor wiring connectors.
7. Connect knock sensor electrical and starter relay connectors.
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Connect wiring harness to intake manifold tab.
8. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors Fig. 4.
9. Connect vacuum hoses to throttle body Fig. 2.
10. Install accelerator, kick down and speed control cables to their bracket and connect them to the throttle lever. Refer to Fuel System, Throttle Body
Installation for procedure.
11. Loose assemble the EGR tube onto valve and intake manifold finger tight Fig. 5.
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Tighten tube fasteners at the EGR valve first to 11 Nm (95 in lb)
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Then, tighten the intake manifold side fasteners to 11 Nm (95 in lb).
12. Connect negative cable from auxiliary jumper Fig. 1.
13. 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 energized for 7 minutes or until the ignition
switch is turned to the OFF position, or Stop All Test is selected.
