Chrysler PT Cruiser. Manual — part 717
(5) Disconnect idle air control (IAC) motor and
throttle position sensor connectors.
(6) Disconnect the MAP sensor connector (Fig.
142).
(7) Remove the throttle control shield (Fig. 143).
(8) Remove the throttle cable from the throttle
body lever (Fig. 144).
(9) If equipped with speed control, remove speed
control cable from the throttle lever by sliding clasp
out hole used for throttle cable.
(10) Remove the 2 screws for the throttle cable
bracket.
(11) Reposition throttle cable bracket (Fig. 145).
(12) Remove intake manifold cover.
NOTE: To remove intake manifold cover, start with
clips near throttle body.
Fig. 142 MAP Sensor - 2.4L Turbo
1 - MAP SENSOR
Fig. 143 Throttle Control Shield 2.4L Turbo
Fig. 144 Throttle Cables - 2.4L Turbo
Fig. 145 Throttle Cable Bracket - 2.4L Turbo
9 - 148
ENGINE 2.4L DOHC
PT
INTAKE MANIFOLD (Continued)
(13) Disconnect brake booster hose and PCV hose
from intake manifold (Fig. 146).
(14) Disconnect purge solenoid hose from throttle
body (Fig. 146).
(15) Remove intake manifold cover.
(16) Remove
upper
intake
manifold
support
bracket (Fig. 147).
(17) Remove upper intake manifold fasteners (Fig.
152).
(18) Remove upper intake manifold.
(19) If further service is required, cover the lower
intake manifold openings to prevent foreign materi-
als from entering the engine (Fig. 139).
LOWER INTAKE MANIFOLD
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING SYSTEM COMPONENTS. SER-
VICE VEHICLES IN WELL VENTILATED AREAS AND
AVOID IGNITION SOURCES. NEVER SMOKE WHILE
SERVICING THE VEHICLE.
NOTE: Turbo charged engines could be equiped
with either an aluminum or a plastic intake mani-
fold.
(1) Perform fuel system pressure release procedure
before attempting any repairs (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
(2) Disconnect negative battery cable.
(3) Remove upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
UPPER - REMOVAL).
(4) Partially drain cooling system below thermo-
stat level (Refer to 7 - COOLING/ENGINE - STAN-
DARD PROCEDURE).
(5) Remove upper radiator hose.
(6) Remove coolant outlet connector and thermo-
stat
(Refer
to
7
-
COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT - REMOVAL).
(7) Disconnect the fuel supply line quick connect at
the fuel rail assembly (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/QUICK CONNECT FITTING -
STANDARD PROCEDURE).
WARNING: WRAP SHOP TOWELS AROUND HOSE
TO CATCH ANY GASOLINE SPILLAGE.
Fig. 146 Vacuum Hoses - 2.4L Turbo
1 - PURGE SOLENOID HOSE
2 - BRAKE BOOSTER HOSE
3 - PCV HOSE
Fig. 147 Support Bracket
1 - FASTENERS
2 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
PT
ENGINE 2.4L DOHC
9 - 149
INTAKE MANIFOLD (Continued)
(8) Disconnect fuel injector wiring harness.
(9) Remove screw attaching the oil dipstick tube to
lower intake manifold (Fig. 148) or (Fig. 149).
(10) Turbocharger Equipped Engine: Remove
fasteners for lower intake manifold support bracket
(Fig. 149).
(11) Remove lower intake manifold fasteners (Fig.
154).
(12) Remove lower intake manifold.
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
(1) Inspect
manifold
for
cracks,
distortion,
or
mounting surface warpage. Replace manifold if nec-
essary.
(2) Inspect manifold gasket for surface damage or
excessive swelling. Replace gaskets as necessary.
INSTALLATION
UPPER INTAKE MANIFOLD
Non-Turbo
(1) If lower intake manifold was covered during
service, remove cover (Fig. 139).
(2) Clean all sealing surfaces. Replace seals as nec-
essary.
(3) Position new seals on manifold.
(4) Position upper intake manifold on lower intake
manifold. Tighten upper intake manifold fasteners to
12 N·m (105 in. lbs.) in sequence shown in (Fig. 150).
Fig. 148 Dipstick Tube
1 - DIPSTICK TUBE
2 - SCREW
Fig. 149 Lower Intake Manifold Support Bracket -
2.4L Turbo
1 - UPPER INTAKE MANIFOLD
2 - LOWER INTAKE MANIFOLD
3 - SUPPORT BRACKET
4 - DIPSTICK TUBE SCREW
Fig. 150 Intake Manifold Tightening Sequence
9 - 150
ENGINE 2.4L DOHC
PT
INTAKE MANIFOLD (Continued)
(5) Connect PCV hose to intake manifold (Fig.
151).
(6) Connect manifold absolute pressure (MAP)
electrical connector (Fig. 134).
(7) Connect proportional purge hoses (Fig. 136).
(8) Connect brake booster hose (Fig. 137).
(9) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors
(Fig. 135).
(10) Install throttle and speed control cables to
bracket. Connect cables to the throttle lever.
(11) Connect negative cable to battery.
(12) Install air cleaner housing and clean air hose.
Tighten clean air hose clamp to 1.7 N·m (15 in. lbs.).
(13) Connect make-up air hose and inlet air tem-
perature sensor (Fig. 151).
Turbo
(1) If lower intake manifold was covered during
service, remove cover (Fig. 139).
(2) Clean
all
sealing
surfaces.
Replace
upper
intake manifold gasket.
NOTE: This engine could be equiped with either a
plastic intake manifold or an aluminum intake man-
ifold.
(3) Position upper intake manifold on lower intake
manifold. On engines equiped with an aluminum
intake manifold, tighten manifold fasteners to 28
N·m (250 in. lbs.) in sequence shown in (Fig. 152).
On engines equiped with a plastic intake manifold,
tighten manifold fasteners to 12 N·m (105 in. lbs.) in
sequence shown in (Fig. 152).
(4) Install upper intake manifold to cylinder head
support bracket (Fig. 147). Torque cylinder head fas-
teners to 28 N·m (250 in. lbs.) and manifold fasteners
to 6 N·m (55 in. lbs.).
(5) Install the intake manifold cover.
(6) Connect purge solenoid hose to throttle body
(Fig. 146).
(7) Connect brake booster vacuum hose and PCV
hose to intake manifold (Fig. 146).
(8) Install the 2 screws for the throttle cable
bracket and tighten to 12 N·m (105 in. lbs.) on alu-
minum intake manifolds and 6 N·m (55 in. lbs.) on
plastic intake manifolds.
(9) If equipped with speed control, install speed
control cable to the throttle lever by sliding clasp in
the hole used for throttle cable.
(10) Install the throttle cable to the throttle body
lever (Fig. 144).
(11) Install the throttle control shield (Fig. 143).
(12) Connect idle air control (IAC) motor and
throttle position sensor connectors.
(13) Connect the MAP sensor connector (Fig. 142).
(14) Connect charge air cooler hose to throttle
body (Fig. 140) and (Fig. 141). Tighten hose clamp to
1.7 N·m (15 in. lbs.).
(15) Connect negative battery cable.
LOWER INTAKE MANIFOLD
NOTE: Turbo charged engines could be equiped
with either an aluminum or a plastic manifold.
Fig. 151 PCV
1 - MAKE-UP AIR HOSE
2 - PCV VALVE
Fig. 152 Intake Manifold Tightening Sequence - 2.4L
Turbo
PT
ENGINE 2.4L DOHC
9 - 151
INTAKE MANIFOLD (Continued)
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