AutoZone 1984 BMW 533I 3.2L FI SOHC 6cyl | Repair Guides | Engine Mechanical | Engine Mechanical Components | Upper Intake Manifold (plenum) | AutoZone.com

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    PT Cruiser 2006-2007

    Upper Intake Manifold (Plenum)

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    Removal & Installation



    Non-Turbo Models
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Remove or disconnect the following:

      The negative battery cable
       
      The Inlet Air Temperature (IAT) sensor and air hose
       
      The engine cover
       
      The throttle and cruise control cables from the throttle lever bracket
       
      The Manifold Absolute Pressure (MAP) sensor
       
      The Idle Air Control (IAC) motor electrical connector
       
      The Throttle Position Sensor (TPS) wiring connector
       
      The proportional purge hoses
       
      The brake booster vacuum hose
       
      The Positive Crankcase Ventilation (PCV) hose from the intake manifold
       
      The throttle body support bracket bolt
       
      The Exhaust Gas Recirculation (EGR) tube from the upper intake manifold
       
      The upper intake manifold
       

    6.  
    7. Clean the mating surfaces.

      Click image to see an enlarged view

      Fig. Remove the EGR tube from the upper intake manifold

    8.  

    To install:

    Click image to see an enlarged view

    Fig. Upper intake manifold bolt torque sequence-Non-Turbo models

    1. Install or connect the following:

      New gaskets and seals
       
      The intake manifold on the EGR tube then on the lower intake manifold. Torque the bolts, in sequence, to 105 inch lbs. (12 Nm)
       
      The throttle body support bracket and torque the bolt to 28 ft. lbs. (20 Nm)
       
      The EGR retainer plate and torque the smaller bolt to 95 inch lbs. (11 Nm) and the large bolt to 28 ft. lbs. (21 Nm)
       
      The PCV hose to the intake manifold
       
      The MAP sensor electrical connector
       
      The proportional purge hoses
       
      The brake booster hose
       
      The IAC motor and TPS connectors
       
      The throttle and speed control cables
       
      The air cleaner assembly
       
      The engine cover
       
      The IAT sensor
       
      The negative battery cable
       

    2.  

    Turbo Models

    NOTE
    The engines in these vehicles are equipped with either an aluminum or plastic manifold.

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Remove or disconnect the following:
      NOTE
      Cover the lower intake manifold to avoid dirt and other objects from entering.



      The negative battery cable
       
      The Inlet Air Temperature (IAT) sensor
       
      The Manifold Absolute Pressure (MAP) sensor
       
      The throttle inlet pressure hose
       
      The charge air cooler hose from the throttle body
       
      The Idle Air Control (IAC) motor electrical connector
       
      The throttle control shield
       
      The throttle and cruise control cables from the throttle lever bracket
       
      The throttle cable bracket
       
      The brake booster vacuum hose
       
      The Positive Crankcase Ventilation (PCV) hose from the intake manifold
       
      The purge solenoid hose from the throttle body
       
      The upper intake manifold support bracket and manifold
       

    6.  
    7. Clean the mating surfaces.
    8.  

    To install:

    Click image to see an enlarged view

    Fig. Upper intake manifold bolt torque sequence-turbo models

    1. Remove the cover from the lower intake manifold.
    2.  
    3. Install or connect the following:

      The new gasket
       
      The intake manifold on the lower intake manifold. If equipped with an aluminum manifold, torque the bolts in sequence to 250 inch lbs. (28 Nm). If equipped with a plastic manifold, torque the bolts in sequence to 105 inch lbs. (12 Nm).
       
      The upper intake manifold support bracket Torque the retainers to 250 inch lbs. (28 Nm).
       
      The purge solenoid hose to the throttle body
       
      The brake booster vacuum hose
       
      The PCV hose
       
      The throttle cable bracket and tighten the screws to 105 inch lbs. (12 Nm)
       
      The throttle and cruise control cables to the throttle lever bracket
       
      The throttle control shield
       
      The IAC motor electrical connector
       
      The MAP sensor
       
      The charge air cooler hose to the throttle body
       
      The IAT sensor
       
      The throttle inlet pressure hose
       
      The negative battery cable
       

    4.  

     
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