OEM 2002 Chrysler PT Cruiser Intake Manifold

2002 Chrysler PT Cruiser Intake Manifold Parts and Q&A

• Q: How to Service and Repair the Lower Intake Manifold on 2002 Chrysler PT Cruiser?

  A: You should release pressure from the fuel system and make sure the area is adequately ventilated before servicing the lower intake manifold, so ignition doesn't come about. Unplug the inlet air temperature sensor and make-up air hose, take off the air cleaner housing and clean the air hose. Loosen the wire for the negative battery terminal and remove the intake manifold from the top of the engine. Drain some of the coolant from the radiator below the thermostat, take out the upper radiator hose, connect the coolant outlet and then take out the thermostat. Cut off the fuel supply line at the fuel rail by undoing the quick connect and lay shop towels around the hose to protect from gasoline dripping. You should remove the fuel injector wiring harness, loosen the screw beneath the oil dipstick tube with the manifold and undo the fasteners of the lower intake manifold before removing it. Toss out the old gasket and thoroughly wipe the areas that seal, inspecting the manifold to see if there are fractures, twists or gasket damage and choose to replace it if this is the case. Wipe all gasket surfaces and assure yourself that the gasket is not damaged, changing it if needed. Replace the seals on the lower intake manifold if they are put in and mount the lower intake manifold, securing all bolts to 12 Nm (105 inch lbs.) following the described sequence. After removing, slide the fuel rail assembly into the intake manifold and tighten all screws to 23 Nm (200 inch lbs.). Join the wires from the fuel injector to the injector harness, watch for signs of damage on the quick connectors and drop some engine oil to the inside of the tube before securing the tube to the fuel rail with the fuel supply hose. Put back the screw for the oil dipstick tube, coolant outlet connector, thermostat and upper radiator hose and next install the upper intake manifold. Put on the negative battery terminal, install the air cleaner housing and clean air hose and reattach the inlet air temperature sensor and make-up air hose. Fill the cooling system and use the Drbiii scan tool to pressurize the system and look for leaks, as the Auto Shutdown relay will power up for 7 minutes unless the ignition is shut off or the Stop All Test is run.