OEM 2003 Chrysler PT Cruiser Intake Manifold

2003 Chrysler PT Cruiser Intake Manifold Parts and Q&A

• Q: How to Service and Repair a Turbocharged Engine's Lower Intake Manifold on 2003 Chrysler PT Cruiser?

  A: When servicing the lower intake manifold on a turbocharged engine, ensure that there is no fuel pressure, that the area is well-ventilated and avoid sparks or open flames. It's important to take off the negative battery cable first, then remove the upper intake manifold from your engine. Dip a little water out of the cooling system below where the thermostat goes, then unhook the hose leading to the top radiator and the connector from the coolant outlet. Turn off the main fuel supply and remove the quick connect from the fuel rail assembly, then put shop towels around the hose to prevent gas from dripping. After that, unconnect the wiring harness from the fuel injectors. Drop the screw connecting the oil dipstick tube to the lower intake manifold and untie both fasteners for the lower intake manifold support bracket. After that, take out all the fasteners on the lower intake manifold and remove the whole part. Throw away the worn gaskets and scrub all places where gaskets seal. Check the manifold for any cracks, distortion or damage to its gasket and change it if you find any of these. To install, make sure all parts are clean and new gasket surfaces are correctly set, before you place the lower intake manifold, tighten all bolts to 28 Nm. Put in the lower intake manifold support bracket fasteners and turn them to 54 Nm (40 ft. lbs.). If you take them off, attach the fuel rail assembly to the lower intake so the screws are tightened to 23 Nm (200 in. lbs.). Attach the fuel injector wiring harness, examine the quick connect fittings, oil all the tubes with clean engine oil and secure the fuel hose to the fuel rail assembly. After removing the old screw, place the new one for the oil dipstick tube on, then fit the coolant outlet connector and the thermostat, next add the upper radiator hose and upper intake manifold. Now, connect the negative battery cable back, fill up the cooling system and press the Asd Fuel System Test with the Drbiii scan tool. Do so while the Asd Relay remains energized for 7 minutes or until the ignition is turned off or Stop All Test is chosen.