PT Cruiser, 2001 - 2005

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:

    Negative battery cable
     
    Inlet Air Temperature (IAT) sensor and air hose
     
    Engine cover
     
    Throttle and cruise control cables from the throttle lever bracket
     
    Manifold Absolute Pressure (MAP) sensor
     
    Idle Air Control (IAC) motor electrical connector
     
    Throttle Position (TPS) sensor wiring connector
     
    Proportional purge hoses
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) hose from the intake manifold
     
    Throttle body support bracket bolt
     
    Exhaust Gas Recirculation (EGR) tube from the upper intake manifold
     
    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
     
    Intake manifold on the EGR tube then on the lower intake manifold. Torque the bolts, in sequence, to 20 ft. lbs. (28 Nm) on 2002 models or 105 inch lbs. (12 Nm) on 2003-06 models.
     
    Throttle body support bracket and torque the bolt to 28 ft. lbs. (20 Nm)
     
    EGR retainer plate and torque the smaller bolt to 95 inch lbs. (11 Nm) and the large bolt to 28 ft. lbs. (21 Nm)
     
    PCV hose to the intake manifold
     
    MAP sensor electrical connector
     
    Proportional purge hoses
     
    Brake booster hose
     
    IAC motor and TPS connectors
     
    Throttle and speed control cables
     
    Air cleaner assembly
     
    Engine cover
     
    IAT sensor
     
    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.



    Negative battery cable
     
    Inlet Air Temperature (IAT) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Throttle inlet pressure hose
     
    Charge air cooler hose from the throttle body
     
    Idle Air Control (IAC) motor electrical connector
     
    Throttle control shield
     
    Throttle and cruise control cables from the throttle lever bracket
     
    Throttle cable bracket
     
    Brake booster vacuum hose
     
    Positive Crankcase Ventilation (PCV) hose from the intake manifold
     
    Purge solenoid hose from the throttle body
     
    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:

    New gasket
     
    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).
     
    Upper intake manifold support bracket Torque the retainers to 250 inch lbs. (28 Nm).
     
    Purge solenoid hose to the throttle body
     
    Brake booster vacuum hose
     
    PCV hose
     
    Throttle cable bracket and tighten the screws to 105 inch lbs. (12 Nm)
     
    Throttle and cruise control cables to the throttle lever bracket
     
    Throttle control shield
     
    IAC motor electrical connector
     
    MAP sensor
     
    Charge air cooler hose to the throttle body
     
    IAT sensor
     
    Throttle inlet pressure hose
     
    Negative battery cable
     

  4.  

 
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