Important Tips

The Majority Of 2.4L Chrysler Fuel Injectors Are Underneath The Upper Intake Manifold Plenum

As mentioned earlier, some vehicles have the fuel injectors under the intake manifold plenum and this plenum has to be removed to test the fuel injectors underneath.

One thing that I have done whenever it's been possible, is to use a fuel injector connector that I have cut from an old Chrysler Wiring Harness. And with a little patience and perseverance, I have disconnected the fuel injector's connector (the one that I'm going to test and that is underneath the plenum) and installed the one I cut from the old wiring harness, and performed the test described in this article by testing the ends of the cut connector (and without having to remove the plenum).

On some, I have just removed the plenum and followed the following tips:

  1. 1

    As I'm removing bolts, nuts, etc., I'm placing them in a container and away from the engine. This is important since I want to avoid having anything fall into the open intake manifold runners that are now exposed with the plenum removed.

  2. 2

    I have clean rags at the ready, and when the plenum is finally off, I then immediately cover the four open intake runners with them. In other words, I stuff those rags into the open intake runners. This will help to keep any foreign metal object from falling into them.

  3. 3

    I use new gaskets. I do not re-use the old intake manifold plenum gasket, and neither should you. Also, when installing the new ones, do not coat them in any type of sealer (like RTV Silicon). This is not necessary and could back fire on you since the sealer can cause a vacuum leak.

If anything falls into an open intake manifold runner, without you knowing it, you are going to be in a world of hurt because once you put everything back together and you start the engine, it's gonna' knock! The only way to remove whatever fell in there, is to remove the engine's cylinder head.

I have removed the intake manifold plenum on these 2.4L (DOHC) many times and without complications. You can too, if you keep in mind the above suggestions.

More Test Articles

If this article confirmed that the fuel injectors are good and not the cause of the rough idle condition or misfire condition, and yet your car (or mini-van) is still running rough, I suggest testing the ignition system. Below are the links to two 2.0L (SOHC, DOHC) and 2.4L (DOHC) Ignition System Test Articles (they are found at easyautodiagnostics.com):

  1. How To Test 2.0L And 2.4L Coil Packs Chrysler, Dodge, Eagle, Plymouth And Mitsubishi.
    1. How to test the ignition coil pack, Spark Plug Wires, and Ignition Coil Pack Signals on all 2.0 (SOHC, DOHC) and 2.4L (DOHC) Chrysler, Dodge, Plymouth, Eagle and Mitsubishi vehicles.
  2. Carbon Tracks Are A Common Cause Of Ignition Misfire!.
    1. This is a real life case study on how to diagnose a misfire condition due to a carbon track on the spark plug wire boot.

Here, at troubleshootmyvehicle.com, you can find all of the 2.0L and 2.4L Chrysler Test Articles by clicking here: Chrysler 2.0L, 2.4L Index Of Articles.

Here's a sample of the tutorials you'll find in the index:

  1. How To Test The Engine Compression (Chrysler 2.0L, 2.4L).
  2. How To Test The Engine Compression (Chrysler 2.0L, 2.4L).
  3. How To Test The Crank Sensor (Chrysler 2.0L, 2.4L).
  4. How To Test Misfire Codes (Chrysler 2.0L, 2.4L).
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Chrysler Vehicles:

  • Cirrus
    • 1995, 1996, 1997, 1998, 1999, 2000
  • Neon
    • 2000, 2001, 2002
  • PT Cruiser
    • 2001, 2002
  • Sebring
    • 1995, 1996, 1997, 1998, 1999, 2001, 2002

Chrysler Vehicles:

  • Voyager
    • 2001, 2002

Dodge Vehicles:

  • Avenger
    • 1995, 1996, 1997, 1998, 1999
  • Caravan & Grand Caravan
    • 1996, 1997, 1998, 1999, 2000, 2001, 2002

Dodge Vehicles:

  • Neon
    • 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002
  • Stratus
    • 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002

Eagle Vehicles:

  • Talon
    • 1995, 1996, 1997, 1998

Mitsubishi Vehicles:

  • Eclipse
    • 1995, 1996, 1997, 1998, 1999

Plymouth Vehicles:

  • Breeze
    • 1996, 1997, 1998, 1999, 2000
  • Neon
    • 1995, 1996, 1997, 1998, 1999, 2000, 2001
  • Voyager & Grand Voyager
    • 1996, 1997, 1998, 1999, 2000