PT Cruiser, 2001 - 2005

Exhaust Manifold

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Removal & Installation



Non Turbo Models
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly and bracket
     
    Throttle and speed control cables
     
    Manifold Absolute Pressure (MAP) sensor electrical connector
     
    Power steering reservoir, move it aside. DO NOT disconnect the fluid lines.
     
    Coolant recovery bottle
     
    Exhaust manifold upper heat shield
     
    Exhaust pipe from the manifold
     
    Engine wiring heat shield
     
    Manifold support bracket
     
    Lower exhaust manifold heat shield
     
    Upstream Heated Oxygen Sensor (HO 2 S) connector
     
    Exhaust manifold and discard the gasket
     

  4.  
  5. Thoroughly clean the mating surfaces.
  6.  

To install:

Click image to see an enlarged view

Fig. Torque the exhaust manifold bolts in sequence

  1. Install or connect the following:

    New gasket
     
    Exhaust manifold and torque the bolts, in sequence, to 17 ft. lbs. (23 Nm)
     
    Alternator bracket bolt, if loosened
     
    Exhaust manifold heat shields and torque the bolts to 105 inch lbs. (12 Nm)
     
    Exhaust manifold support bracket
     
    Engine wiring heat shield
     
    Upstream HO 2 sensor wiring connector
     
    Exhaust pipe to the manifold and torque the bolts to 21 ft. lbs. (28 Nm)
     
    Coolant recovery bottle
     
    Power steering pump reservoir
     
    MAP sensor connector
     
    Throttle and speed control cables
     
    Air cleaner bracket and assembly
     
    Negative battery cable
     

  2.  
  3. Start the vehicle and check for leaks, repair if necessary.
  4.  

Turbo Models

The exhaust manifold on turbocharged models is removed as an assembly with the turbocharger. Refer to the Turbocharger Removal and Installation procedure for manifold removal.

 
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