OEM 2004 Chrysler PT Cruiser Intake Manifold

2004 Chrysler PT Cruiser Intake Manifold Parts and Q&A

• Q: How to Service and Repair an Upper Intake Manifold on a Turbo Engine on 2004 Chrysler PT Cruiser?

  A: You should start by unplugging the negative battery cable, then take out the inlet air temperature, throttle inlet pressure, charge air cooler, idle air control, throttle position and MAP sensors. Take off the shield covering the throttle control and pull the cable out of the throttle body lever. Should your throttle have a speed control feature, pull out the speed control cable from the throttle lever. Loosen the two screws on the throttle cable bracket and put it back where you want. Remove the hose from the intake manifold that is linked to the brake booster, PCV and purge solenoid opening. After removing the intake manifold support bracket, unscrew the upper intake fasteners and then remove the manifold. If you notice you need to give the engine more service, make sure to block off the lower intake manifold openings so debris doesn't get into the engine. Where the lower intake is covered, remove the cover, clean the sealed areas and then replace the gasket for the upper intake manifold. Locate the upper intake manifold under lower intake manifold, tighten them to 28 Nm (250 in. lbs.) in sequence, using specified fasteners. Lift and position the upper intake manifold support and then fix it with the prescribed torque (28 Nm or 250 in. lbs.). Connect one end of the purge solenoid hose to the throttle body, another to the brake booster vacuum hose and the third to the PCV hose at the intake manifold. Fit the screws into the throttle cable bracket holes and tighten them to 12 Nm (105 in. lbs.). Should your throttle have speed control, attach the speed cable to the lever. After fitting the throttle cable to the lever, install the throttle control shield. The next step is to link up the idle air control (IAC) motor, throttle position sensor and MAP sensor. Then, slide the charge air cooler hose onto the throttle body, tighten the hose clamp to 1.7 Nm (15 in. lbs.) and attach the negative cable from the battery.