OEM 2005 Chrysler PT Cruiser Intake Manifold

2005 Chrysler PT Cruiser Intake Manifold Parts and Q&A

• Q: How to Remove and Install an Intake Manifold for Both Non-Turbo and Turbo Engines on 2005 Chrysler PT Cruiser?

  A: You should begin by taking out the inlet air temperature sensor and the make-up air hose from the clean air hose. When that's done, remove the air cleaner housing and the clean air hose assembly. Remove the negative battery cable first, then the cables from the throttle lever and bracket for the throttle and speed. Following this, unplug the manifold absolute pressure sensor, idle air control motor, throttle position sensor and the three purge, brake booster and PCV hoses from the intake manifold. Before removing the upper intake manifold, take off the bracket that supports the rear intake manifold and all of the fasteners. If extra service is necessary, block the openings in the lower intake manifold to protect the engine from foreign particles. On turbo engines, cut off the negative battery cable, disconnect the inlet air temperature sensor, the throttle inlet pressure hose, the charge air cooler hose from the throttle body, the IAC motor, the throttle position sensor and the MAP sensor. Withdraw the throttle control shield and its cable from the lever on the throttle body, straighten the cable bracket and remove the intake manifold cover, starting with the clips next to the throttle body. Undo the brake booster hose, PCV hose and purge solenoid hose from the throttle body and then remove the upper intake manifold support bracket and its fasteners before you can take off the upper intake manifold. In case you need to provide extra service, block the lower intake manifold openings. While cleaning, remove the gaskets, clean every seal area, check the manifold for cracks, distortion or warpage and replace it if anything is found. Look for damage or swelling in the manifold gasket and change it if required. To fit the upper intake manifold on non-turbo engines, lift the cover if the lower manifold was covered, wipe the sealing surfaces and set the new seals in place. Connect the upper intake manifold to the lower intake manifold, then screw on all fasteners to 12 Nm (105 inch lbs.) in the order described. Once the PCV hose is in place, join the MAP connector, proportional purge hoses, brake booster hose, IAC motor and TPS wires, install the throttle and speed control cables to the bracket and connect them to the throttle lever. Attach the negative battery cable again, then place the air cleaner housing and air hose, tighten the clean air hose clamp so it displays 1.7 Nm (or 15 inch lbs) and attach the make-up air hose and inlet air temperature sensor. If the lower intake manifold is under the cover on a turbo engine, start by cleaning all the sealing areas. Then, take off the cover and the large gasket and clean around them. Put the upper intake manifold on the lower intake manifold and use fasteners on aluminum manifolds to 28 Nm (250 inch lbs.) or on plastic manifolds to 12 Nm (105 inch lbs.). Put the upper intake manifold onto the cylinder head support bracket and tighten the cylinder head fasteners and manifold fasteners to the suggested torque settings. After that, set the intake manifold cover in place. Couple the purge solenoid hose to the throttle body, to the brake booster vacuum hose and to the PCV hose on the intake manifold. Screw the throttle cable bracket on and tighten the screws to the correct pressure for your manifold. If your throttle has a speed limit control, install the wire from the cable to the throttle lever and plug the throttle cable into the throttle body lever and shield. Lastly, link the IAC motor with the throttle position sensor, attach the charge air cooler hose to the motor by tightening the hose clamp to 17 Newton-millimeters (15 inch lbs.), join the MAP sensor to the throttle body and put the negative battery cable back on.