Chrysler PT Cruiser. Manual — part 214
(19) Remove remaining intake manifold retaining
bolts and remove manifold from engine (Fig. 69).
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
(1) Inspect
manifold
for
cracks
or
distortion.
Replace manifold if necessary.
(2) Inspect manifold for gasket surface damage or
warpage. Replace manifold if necessary.
INSTALLATION
(1) Clean gaskets/seals mating surfaces.
(2) Install new intake manifold seals on intake
manifold (Fig. 70).
(3) Place intake on cylinder head and install
retaining bolts (Fig. 69). Be sure to install high
pressure fuel line brackets in proper position
(Fig. 68). Torque bolts to 20N·m (14.7 lbs.ft.).
(4) Connect air inlet hose at intake manifold (Fig.
69).
(5) Connect swirl valve actuator hose at actuator
(Fig. 68).
(6) Lower radiator and cooling fan assembly in
vehicle. Attach charge air cooler to radiator.
(7) Attach A/C condenser to radiator with retain-
ing screws.
(8) Connect both A/C lines at condenser.
(9) Raise vehicle on hoist.
(10) Connect cooling fan electrical connector.
(11) Connect lower radiator hose at radiator.
(12) Lower vehicle.
(13) Connect upper radiator hose at radiator.
(14) Install radiator closure panel (Refer to 23 -
BODY/EXTERIOR/RADIATOR
CROSSMEMBER
-
INSTALLATION).
(15) Install front grille assembly (Refer to 23 -
BODY/EXTERIOR/GRILLE - INSTALLATION).
(16) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(17) Evacuate and recharge air conditioning sys-
tem (Refer to 24 - HEATING & AIR CONDITION-
ING - STANDARD PROCEDURE).
(18) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(19) Connect negative battery cable.
Fig. 69 Intake Manifold
1 - INTAKE MANIFOLD
2 - INTAKE MANIFOLD RETAINING BOLTS
3 - INTAKE INLET HOSE
Fig. 70 Intake Manifold Seals
1 - INTAKE MANIFOLD
2 - INTAKE MANIFOLD SEALS
9 - 52
ENGINE
PT
INTAKE MANIFOLD (Continued)
AIR CLEANER ELEMENT
REMOVAL
(1) Unfasten clasps on sides of air cleaner housing
cover. Lift cover off air cleaner housing (Fig. 71).
(2) Remove filter element.
(3) If necessary, clean the inside of the air cleaner
housing.
INSTALLATION
(1) Install new filter element.
(2) Place cover over air cleaner housing. Snap
clasps in place.
AIR CLEANER HOUSING
DESCRIPTION
The air cleaner housing attaches to the inner
fender in front of the left side strut tower (Fig. 72).
An ambient air duct supplies underhood air for the
engine. It attaches to the lower air cleaner box.
REMOVAL
AIR CLEANER HOUSING
(1) Disconnect
turbocharger
inlet
hose
at
air
cleaner (Fig. 72).
(2) Pull air cleaner housing straight up to remove
(Fig. 72).
(3) Remove the inlet duct from the air cleaner
housing (Fig. 72).
Fig. 71 Air Cleaner Cover - Typical
Fig. 72 Air Cleaner Housing Assembly
1 - TURBOCHARGER INLET HOSE
2 - MAF SENSOR RETAINING BOLT
3 - MAF SENSOR
4 - O-RING
5 - MAF SENSOR ELECTRICAL CONNECTOR
6 - AIR CLEANER ASSEMBLY
7 - INLET DUCT
8 - AIR CLEANER HOUSING ASSEMBLY BRACKET
PT
ENGINE
9 - 53
REMOVAL
(1) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(2) Disconnect turbocharger inlet hose at MAF
sensor (Fig. 73).
(3) Disconnect turbocharger inlet hose at turbo-
charger and remove inlet tube (Fig. 74).
INSTALLATION
AIR CLEANER HOUSING
Make sure that the rubber grommets, for the lower
pins, are in place when reinstalling the air cleaner
housing (Fig. 72). The rubber grommet for the PDC
bracket must be installed also.
(1) Install air inlet duct into air cleaner housing
(Fig. 72).
(2) Lower air cleaner housing assembly into engine
compartment and align studs at bottom of housing
with bracket. Push housing assembly down until
fully seated in bracket (Fig. 72).
(3) Connect turbocharger inlet hose to air cleaner
assembly (Fig. 72).
INSTALLATION
(1) Connect turbocharger inlet hose at turbo-
charger (Fig. 74).
(2) Connect turbocharger inlet hose at MAF sensor
(Fig. 73).
(3) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
ENGINE MOUNTING
DESCRIPTION
The engine mounting system consists of a four-
point system utilizing two load-carrying mounts and
two torque struts. The load-carrying mounts are
located on each frame rail. The right mount is a
hydro-elastic mount and left mount is a conventional
elastomeric isolator. The two torque controlling struts
are attached at the front of the engine, straddling the
right side load-carrying mount. The upper strut con-
nects to the suspension strut tower and the lower to
the suspension crossmember.
Fig. 73 Air Cleaner Housing Assembly
1 - TURBOCHARGER INLET HOSE
2 - MAF SENSOR RETAINING BOLT
3 - MAF SENSOR
4 - O-RING
5 - MAF SENSOR ELECTRICAL CONNECTOR
6 - AIR CLEANER ASSEMBLY
7 - INLET DUCT
8 - AIR CLEANER HOUSING ASSEMBLY BRACKET
Fig. 74 Turbocharger Inlet Hose
1 - TURBOCHARGER INLET HOSE
2 - TURBOCHARGER
9 - 54
ENGINE
PT
AIR CLEANER HOUSING (Continued)
OPERATION
The four-point engine mounting system minimizes
the transmission of structure-borne engine noise to
the passenger compartment. The load-carrying right
and left mounts dampen and isolate vertical motion
and vibration. The two struts absorbs torque reaction
forces and torsional vibrations.
TORQUE STRUT
REMOVAL
REMOVAL - UPPER
(1) Remove bolts attaching upper torque strut to
shock tower bracket and engine mount bracket (Fig.
75).
(2) Remove the upper torque strut.
REMOVAL - LOWER
(1) Raise vehicle on hoist.
(2) Remove accessory drive belt splash shield (Fig.
76).
(3) Remove pencil strut (Fig. 77).
(4) Remove bolts attaching lower torque strut to
crossmember and strut bracket (Fig. 77).
(5) Remove lower torque strut.
INSTALLATION
UPPER
(1) Position the upper torque strut into mounting
location (Fig. 75).
(2) Install the torque strut mounting bolts and
perform the torque strut adjustment procedure (Refer
to
9
-
ENGINE/ENGINE
MOUNTING/TORQUE
STRUT - ADJUSTMENTS).
LOWER
(1) Position lower torque strut into mounting loca-
tions.
(2) Install mounting bolts and perform torque
strut adjustment procedure (Refer to 9 - ENGINE/
ENGINE MOUNTING/TORQUE STRUT - ADJUST-
MENTS).
(3) Install pencil strut and tighten nuts to 58 N·m
(43 ft. lbs.) (Fig. 77).
Fig. 75 Engine Mounting - Right Side
1 - BOLT
2 - RIGHT FENDER
3 - UPPER TORQUE STRUT BRACKET
4 - NUTS
5 - BOLT
6 - UPPER TORQUE STRUT
7 - BOLT
8 - LOWER TORQUE STRUT
9 - BOLT
10 - RIGHT ENGINE MOUNT
PT
ENGINE
9 - 55
ENGINE MOUNTING (Continued)
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