Chrysler PT Cruiser. Manual — part 718
(1) Clean all gasket surfaces.
(2) Naturally Aspirated Engine: Position new
seals on lower intake manifold. (Fig. 153).
(3) Naturally Aspirated Engine: Install lower
intake manifold. Tighten fasteners to 12 N·m (105 in.
lbs.) in sequence shown in (Fig. 154).
(4) Turbocharged Engine: Replace lower intake
manifold gasket.
(5) Turbocharged Engine: Install lower intake
manifold. If equiped with an aluminum manifold,
tighten fasteners to 28 N·m (250 in. lbs.) in sequence
shown in (Fig. 154).If equiped with a plastic mani-
fold, tighten fasteners to 12 N·m (105 in. lbs.) in
sequence shown in (Fig. 154)
(6) Turbocharger Equipped Engine: Install fas-
teners for lower intake manifold support bracket
(Fig. 149). If equiped with an aluminum manifold,
torque fasteners to 54 N·m (40 ft. lbs.).If equiped
with a plastic manifold, torque manifold fasteners to
6 N·m (55 in. lbs.).
(7) If removed, install the fuel rail assembly to
intake manifold. Tighten screws to 23 N·m (200 in.
lbs.).
(8) Connect fuel injector wiring harness.
(9) Inspect quick connect fittings for damage,
replace if necessary (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/QUICK CONNECT FITTING -
STANDARD PROCEDURE). Lubricate tube with
clean engine oil. Connect fuel supply hose to fuel rail
assembly. Check connection by pulling on connector
to insure it locked into position.
(10) Install the screw attaching the oil dipstick
tube to lower intake manifold (Fig. 148) or (Fig. 149).
(11) Install coolant outlet connector and thermo-
stat
(Refer
to
7
-
COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT - INSTALLATION).
(12) Install radiator upper hose.
(13) Install upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
UPPER - INSTALLATION).
(14) Connect negative cable to battery.
(15) Fill the cooling system (Refer to 7 - COOL-
ING/ENGINE - STANDARD PROCEDURE).
(16) With the DRBIII
t scan tool use ASD Fuel
System Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
Fig. 153 Lower Intake Manifold Seals - Naturally
Aspirated Engine
1 - SEALS
Fig. 154 Lower Intake Manifold Tightening
Sequence
9 - 152
ENGINE 2.4L DOHC
PT
INTAKE MANIFOLD (Continued)
EXHAUST MANIFOLD
REMOVAL
NOTE: The exhaust manifold on Turbocharged
equipped vehicles is serviced as an assembly with
the Turbocharger. (Refer to 11 - EXHAUST SYSTEM/
TURBOCHARGER
SYSTEM/TURBOCHARGER
-
REMOVAL).
(1) Remove clean air hose and air cleaner housing.
(2) Disconnect negative cable from battery.
(3) Disconnect throttle and speed control cables
from the throttle lever and bracket.
(4) Disconnect MAP sensor electrical connector.
(5) Remove fasteners securing power steering fluid
reservoir to cylinder head.
(6) Remove coolant recovery container (Refer to 7 -
COOLING/ENGINE/COOLANT RECOVERY CON-
TAINER - REMOVAL).
(7) Remove bolts attaching upper heat shield (Fig.
155).
(8) Remove upper heat shield.
(9) Raise vehicle.
(10) Disconnect exhaust pipe from manifold (Fig.
156).
(11) Remove engine wiring heat shield (Fig. 157).
Fig. 156 Exhaust Manifold To Pipe Connection
1 - GASKET
2 - CATALYTIC CONVERTER
3 - NUT
Fig. 157 Heat Shield—Engine Wiring
1 - HEAT SHIELD
2 - NUT
3 - NUT
Fig. 155 Exhaust Manifold Heat Shield Bolts
1 - BOLTS
PT
ENGINE 2.4L DOHC
9 - 153
(12) Remove manifold support bracket (Fig. 158).
(13) Remove lower exhaust manifold heat shield
(Fig. 159).
(14) Disconnect oxygen sensor electrical connector.
(15) Remove exhaust manifold lower retaining fas-
teners.
(16) Lower vehicle and remove the upper exhaust
manifold retaining fasteners.
(17) Remove exhaust manifold (Fig. 160) from
above/between the engine and cowl panel.
(18) Remove and discard manifold gasket.
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
NOTE: The exhaust manifold on Turbocharged
equipped vehicles is serviced as an assembly with
the Turbocharger. (Refer to 11 - EXHAUST SYSTEM/
TURBOCHARGER
SYSTEM/TURBOCHARGER
-
INSTALLATION).
(1) Install a new exhaust manifold gasket. DO
NOT APPLY SEALER.
(2) Position exhaust manifold in place. Tighten fas-
teners, starting at center and progressing outward in
both directions to 23 N·m (200 in. lbs.) (Fig. 160).
Raise and lower vehicle for fastener access as neces-
sary. Repeat tightening procedure until all fasteners
are at specified torque.
(3) Install exhaust manifold heat shields (Fig.
159). Tighten bolts to 12 N·m (105 in. lbs.) (Fig. 155).
(4) Install exhaust manifold support bracket (Fig.
158).
(5) Install engine wiring heat shield (Fig. 157).
(6) Connect oxygen sensor electrical connector.
(7) Install exhaust pipe to manifold (Fig. 156).
Tighten fasteners to 28 N·m (250 in. lbs.).
(8) Install coolant recovery container (Refer to 7 -
COOLING/ENGINE/COOLANT RECOVERY CON-
TAINER - INSTALLATION).
Fig. 158 Exhaust Manifold Support Bracket
Fig. 159 Exhaust Manifold Heat Shields
1 - UPPER HEAT SHIELD
2 - LOWER HEAT SHIELD
Fig. 160 Exhaust Manifold Tightening Sequence
9 - 154
ENGINE 2.4L DOHC
PT
EXHAUST MANIFOLD (Continued)
(9) Install fasteners securing power steering fluid
reservoir to cylinder head.
(10) Connect MAP sensor electrical connector.
(11) Connect throttle and speed control cables to
the throttle lever and bracket.
(12) Connect negative cable to battery.
(13) Install clean air hose and air cleaner housing.
TIMING BELT COVER(S)
REMOVAL
FRONT COVER—UPPER
(1) Remove upper torque strut attaching bolts and
set strut aside (Refer to 9 - ENGINE/ENGINE
MOUNTING/TORQUE STRUT - REMOVAL).
(2) Turbocharger equipped vehicles:
• Discharge and evacuate and air conditioning
system (Refer to 24 - HEATING & AIR CONDITION-
ING - STANDARD PROCEDURE).
• Disconnect air conditioning lines at junction
block near upper timing belt cover.
(3) Remove upper timing belt cover fasteners (Fig.
161) and remove cover.
FRONT COVER—LOWER
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist. Remove right front
wheel.
(3) Remove the right splash shield.
(4) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(5) Remove crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(6) Remove the lower torque strut (Refer to 9 -
ENGINE/ENGINE MOUNTING/TORQUE STRUT -
REMOVAL).
(7) Disconnect exhaust system from manifold.
(8) Disconnect A/C pressure switch at rear of com-
pressor housing.
(9) Lower vehicle and support engine with a jack.
(10) Discharge A/C system and disconnect A/C
lines at coupling block (Refer to 24 - HEATING &
AIR CONDITIONING - STANDARD PROCEDURE).
(11) Remove upper torque strut (Refer to 9 -
ENGINE/ENGINE MOUNTING/TORQUE STRUT -
REMOVAL).
(12) Remove screw attaching ground strap to strut
bracket.
(13) Remove torque strut bracket from strut tower.
(14) Remove upper radiator closure panel (Refer to
23 - BODY/EXTERIOR/RADIATOR CLOSURE PAN-
EL- REMOVAL).
(15) Remove power steering pump and bracket. Set
pump aside. Do not disconnect lines from pump.
(16) With engine properly supported, remove right
engine mount through bolt.
(17) Raise engine with jack until engine support
bracket bolts are accessible (Fig. 162).
(18) Remove engine support bracket (Fig. 162).
(19) Remove
timing
belt
cover
fasteners
and
remove cover (Fig. 161).
Fig. 161 Front Timing Belt Covers
1 - UPPER COVER FASTENERS
2 - LOWER COVER FASTENERS
PT
ENGINE 2.4L DOHC
9 - 155
EXHAUST MANIFOLD (Continued)
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