OEM 2008 Chrysler PT Cruiser Intake Manifold

2008 Chrysler PT Cruiser Intake Manifold Parts and Q&A

• Q: How to Remove and Replace an Intake Manifold on 2008 Chrysler PT Cruiser?

  A: If the lower intake manifold cover was on during the last service, the upper intake manifold cannot be reached so you will need to remove the cover. Make sure all the surfaces that seal are cleaned and when needed, replace seals. Install each seal on the manifold and after that, put both intake manifolds together, carefully tightening the fasteners to 12 Nm (105 in. lbs.) in the proper order. Connect the PCV hose to the intake manifold as the first step, then install the manifold absolute pressure (MAP) electrical connector and finally handle the proportional purge hoses. Once you have attached the brake booster hose, join the wires for the Idle Air Control (IAC) motor and Throttle Position Sensor (TPS). Fix the throttle and speed control cables to the bracket and assemble them on the throttle lever. After connecting the negative cable to the battery, insert the air cleaner housing and the clean air hose and tighten the clean air hose clamp to 1.7 Nm (15 in. lbs.). In the end, attaching the make-up air hose and the inlet air temperature sensor is necessary. If the lower intake is covered in covered turbo models during service, take off the cover, make the seal surfaces clean and put in a new upper intake manifold gasket. Line up the upper and lower intake manifolds, making sure they are pressed tightly and tighten their fasteners to the required 28 Nm (250 in. lbs.) for aluminum or 12 Nm (105 in. lbs.) for plastic. Attach the upper intake manifold to the cylinder head support bracket, secure the cylinder head bolts to 28 Nm (250 in. lbs.) and the intake manifold bolts to 6 Nm (55 in. lbs.). Put on the intake manifold cover, make the purge solenoid hose connection with the throttle body and connect both the brake booster vacuum and PCV hoses to the intake manifold. Attach the throttle cable bracket with two screws and tighten them to 12 Nm in aluminum or 6 Nm in a plastic intake manifold. Place the throttle control shield, hook up the IAC motor and throttle position sensor connections and install the MAP sensor assembly. Next, attach the end of the charge air cooler hose to the throttle body after tightening the clamp to 1.7 Nm (15 in. lbs.), finally reconnect the negative battery cable.