OEM 2003 Chrysler PT Cruiser Exhaust Manifold

2003 Chrysler PT Cruiser Exhaust Manifold Parts and Q&A

• Q: How to Maintain an Exhaust Manifold and Turbocharger on 2003 Chrysler PT Cruiser?

  A: Start by taking off the negative battery cable and emptying the cooling system before any other work. After removing the air cleaner housing and its lid, pull the clean air hose off the turbocharger and free the throttle and speed control cables from the throttle body. Unhook the connectors from both ends of the Inlet Air Temperature Sensor, MAP Sensor, IAC Motor, Throttle Position Sensor, Ignition Coil Capacitor and Upstream Oxygen Sensor. Then, pull the inlet hoses from the throttle body and upper intake manifold after disconnecting them, detach the bracket holding the upper intake manifold in place and lift out the upper intake manifold, always keeping the lower intake manifold opening plugged to prevent any objects from getting in. Take off the turbocharger's upper heat shield, detach the oil line from it and disconnect the vacuum pipes from the turbo. Elevate the vehicle with a hoist, disconnect the muffler's ground strap and get rid of the muffler. Release the downstream oxygen sensor, remove the bolts attaching the catalytic converter to the exhaust manifold and then take them both out together. Following this, replace the air cooler hose assembly, turbocharger elbow support, turbocharger bracket, oil return pipe, coolant tube, lower heat shield and elbow. Release the lower connections that are accessible with the car on the hoist, lower the car and remove the upper exhaust manifold fasteners after that. Ultimately, take off the turbocharger/exhaust manifold from above/between the engine and cowl panel, along with the gasket and dump them both. Before installing, clean where the gasket will go, replace the gasket without adding sealer and have the stainless steel part face the cylinder head, while the graphite side goes against the manifold. With the engine and head off the vehicle, insert the turbocharger/exhaust manifold assembly from below/between the engine and cowl panel, fit it in place and first tighten the fasteners at the center to 28 Nm (250 in. lbs.), moving to the edges slowly. Tighten the fasteners in turn until all are up to the required torque level. Fit the turbocharger elbow next, attach all the fasteners to it (to 28 Nm) and then fit the heat shield, offer a new gasket on the oil return line, fit the oil return tube and torque the installation fasteners to 12 Nm. Fit the support bracket for the turbocharger by tightening M8 fasteners to 28 Nm (250 in. lbs.) and M10 fasteners to 54 Nm (40 ft. lbs.), then attach the turbocharger elbow support bracket and the turbocharger to charge air cooler hose assembly. Reinstall the catalytic converter and intermediate pipe as a united part, connecting it to the exhaust manifold with T-bolts at a torque of 28 Nm (250 in. lbs.). Afterward, fasten the muffler to the main engine assembly and fix in place the muffler ground strap. Attach the back oxygen sensor, lower your vehicle and plug the turbocharger's vacuum hoses in place. Put in the coolant return line using new washers(tighten banjo fitting bolt to 30 Nm (22 ft. lbs.)), connect the oil supply line to the turbocharger (tighten flared fitting to 31 Nm (23 ft. lbs.)) and attach the turbocharger upper heat shield, fastening all components to 28 Nm (250 in. lbs.). Set the upper intake manifold in place and secure its bracket, join the vacuum piping between the throttle and the upper intake and join the air inlet hose at the throttle body. After removing the connectors, connect the IAT Sensor, MAP Sensor, IAC Motor, Throttle Position Sensor, Ignition Coil Capacitor and Upstream Oxygen Sensor to the system, then attach the cables at the throttle body and connect the clean air hose at the turbocharger. Hang the air cleaner housing, place the lid on top, fill the cool system, alter the oil and filter and reattach the negative battery cable.