PT Cruiser, 2001 - 2005

Intake Manifold

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Removal & Installation



Lower Manifold

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. Drain the coolant system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Inlet Air Temperature (IAT) sensor and make-up hose
     
    Air cleaner
     
    Upper intake manifold
     
    Upper radiator hose and coolant outlet connector
     
    Fuel supply line quick-connect from the fuel rail
     
    Fuel injector wiring harness
     
    Oil dipstick tube from the lower intake manifold
     
    Intake manifold and discard the gaskets and seals
     

  8.  
  9. Thoroughly clean the gasket mating surfaces.
  10.  

To install:

Click image to see an enlarged view

Fig. Install new seals on the lower intake manifold-Non-Turbo models



Click image to see an enlarged view

Fig. Lower intake manifold bolt torque sequence

  1. Install or connect the following:

    New seals on Non-Turbo models
     
    Intake manifold and torque the bolts in sequence to 105 inch lbs. (12 Nm) on Non-Turbo models
     
    New gaskets on turbo models
     
    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 150 inch lbs. (12 Nm) on turbo models.
     
    Lower intake manifold support bracket retainers on turbocharged models to 40 ft. lbs. (54 Nm)
     
    Fuel injector wiring harness
     
    Fuel supply line quick-connect to the fuel tube assembly
     
    Oil dipstick tube to the lower intake manifold
     
    Upper radiator hose
     
    Upper intake manifold
     
    IAT sensor
     
    Air cleaner assembly
     
    Negative battery cable
     

  2.  
  3. Fill the coolant system.
  4.  
  5. Pressurize the fuel system.
  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

 
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