Chrysler PT Cruiser. Manual — part 716
INSTALLATION
(1) Inspect oil jet o-ring (Fig. 128).
(2) Lightly coat o-ring with clean engine oil.
(3) Push oil jet into engine block until it is fully
seated.
CAUTION: Ensure oil jet is fully seated in engine
block before installing fastener. Do Not use the oil
jet fastener to draw the oil jet into the engine block.
Damage to oil jet may occur.
(4) Install oil jet fastener. Torque fastener to 12
N·m (105 in. lbs.) (Fig. 127).
(5) Install crankshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT - INSTALLATION).
OIL COOLER & LINES - 2.4L
TURBO
DESCRIPTION
An engine oil cooler is used on the 2.4L Turbo-
charged engine. The cooler is a coolant-to-oil type
and mounted between the oil filter and oil filter
adapter (Fig. 129).
REMOVAL
(1) Raise vehicle on hoist.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(3) Disconnect oil cooler coolant hoses (Fig. 129).
(4) Remove oil filter.
(5) Remove oil cooler connector bolt (Fig. 130).
(6) Remove oil cooler.
Fig. 128 Oil Jet O-ring
1 - OIL JET
2 - O-RING
Fig. 129 Oil Cooler and Lines
1 - COOLANT TUBES
2 - COOLANT HOSES
3 - OIL FILTER
4 - OIL COOLER
Fig. 130 Oil Cooler Connector Bolt
1 - OIL COOLER
2 - CONNECTOR BOLT
9 - 144
ENGINE 2.4L DOHC
PT
OIL JET - 2.4L TURBO (Continued)
INSTALLATION
(1) Replace oil cooler seal (Fig. 131).
(2) Lubricate seal and position oil cooler to oil fil-
ter adapter, aligning notch to tab (Fig. 132).
(3) Install oil cooler connector bolt. Torque connec-
tor bolt to 55 N·m (41 ft. lbs.) (Fig. 130).
(4) Install oil filter.
(5) Connect oil cooler coolant hoses (Fig. 129).
(6) Lower vehicle.
(7) Fill cooling system (Refer to 7 - COOLING/EN-
GINE - STANDARD PROCEDURE).
INTAKE MANIFOLD
DIAGNOSIS AND TESTING
INTAKE MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM’S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
UPPER INTAKE MANIFOLD
Non-Turbo
(1) Disconnect inlet air temperature sensor and
make-up air hose from clean air hose (Fig. 133).
(2) Remove air cleaner housing and clean air hose
assembly.
(3) Disconnect negative cable from battery.
Fig. 131 Oil Cooler Seal
1 - OIL COOLER SEAL
Fig. 132 Oil Cooler Alignment
1 - NOTCH
2 - TAB
Fig. 133 PCV
1 - MAKE-UP AIR HOSE
2 - PCV VALVE
PT
ENGINE 2.4L DOHC
9 - 145
OIL COOLER & LINES - 2.4L TURBO (Continued)
(4) Remove throttle and speed control cables from
throttle lever and bracket.
(5) Disconnect manifold absolute pressure (MAP)
sensor (Fig. 134), idle air control (IAC) motor and
throttle position sensor (TPS) wiring connectors (Fig.
135).
(6) Disconnect proportional purge hoses (Fig. 136).
(7) Disconnect brake booster hose (Fig. 137).
(8) Disconnect PCV hose from intake manifold
(Fig. 133).
Fig. 134 MAP Sensor
1 - MAP SENSOR
Fig. 135 Idle Air Control (IAC) Motor and Throttle
Position Sensor (TPS) Wiring Connectors
1 - IAC
2 - PCM
3 - TPS
Fig. 136 Proportional Purge Hoses
1 - PROPORTIONAL PURGE HOSES
Fig. 137 Brake Booster Hose
9 - 146
ENGINE 2.4L DOHC
PT
INTAKE MANIFOLD (Continued)
(9) Remove rear intake manifold support bracket
(Fig. 138).
(10) Remove upper intake manifold fasteners (Fig.
150).
(11) Remove upper intake manifold.
(12) If further service is required, cover the lower
intake manifold openings to prevent foreign materi-
als from entering the engine (Fig. 139).
Turbo
NOTE: This engine could be equiped with an alumi-
num Intake manifold or a plastic intake manifold.
(1) Disconnect negative battery cable.
(2) Disconnect the inlet air temperature (IAT) sen-
sor connector (Fig. 140).
(3) Disconnect the throttle inlet pressure (TIP)
hose (Fig. 140).
(4) Disconnect charge air cooler hose at throttle
body (Fig. 140) and (Fig. 141).
Fig. 138 INTAKE MANIFOLD SUPPORT
1 - INTAKE MANIFOLD SUPPORT BRACKET
Fig. 139 Cover Lower Intake Manifold Openings
1 - INTAKE MANIFOLD MUST BE COVERED DURING SERVICE
Fig. 140 IAT Sensor - 2.4L Turbo
1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY
2 - IAT SENSOR
3 - TIP HOSE
Fig. 141 Charge Air Cooler Hoses
1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY
2 - CHARGE AIR COOLER
3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
PT
ENGINE 2.4L DOHC
9 - 147
INTAKE MANIFOLD (Continued)
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