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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