OEM 2009 Chrysler PT Cruiser Intake Manifold

2009 Chrysler PT Cruiser Intake Manifold Parts and Q&A

• Q: How to Remove and Replace the Intake Manifold on a Non-Turbo Engine on 2009 Chrysler PT Cruiser?

  A: If the lower intake manifold was covered prior to your service, make sure to remove the cover prior to moving on. Clean every seal area and put in new seals if they are worn down. Attach the new seals to the manifold, set the upper intake manifold on the lower intake manifold and fasten all the fasteners to 12 Nm (105 in. lbs.) in the proper order. Attach the PCV hose to where it connects to the intake manifold, to the manifold absolute pressure (MAP) electrical connector and to the proportional purge hoses. Link the brake booster hose, the Idle Air Control (IAC) motor and the Throttle Position Sensor (TPS) wiring connectors. Connect the throttle and speed control cables to the bracket and then fasten the other end to the throttle lever. After this, connect the battery's negative cable to the link terminal and fix the air cleaner housing and clean air tube, tightening the clamp on the air hose to 1.7 Nm (15 in. lbs.). After that, secure the make-up air hose and install the inlet air temperature sensor. If you have covered the intake manifold during service, remove the cover, clean the sealing areas and install a new upper intake manifold gasket. Set the given sequence for the fasteners and tighten them to the specified torque: 28 Nm (250 in. lbs.) for aluminum manifolds and 12 Nm (105 in. lbs.) for plastic manifolds. Fit the upper intake manifold to the cylinder head support bracket, then secure the bolts to 28 Nm for the cylinder head and 6 Nm for the manifold. Attach the cover to the manifold, join the purge solenoid tube to the throttle body and join both the brake booster vacuum and PCV hoses to the intake manifold. Screw in the both screws for the throttle cable bracket, following the instruction for your intake manifold material. Attach the throttle control shield, link the IAC motor and throttle position sensor connectors to the system and additionally attach the MAP sensor connector. Connect the charge air cooler hose to the throttle body, tighten the clamp to 1.7 Nm (15 in. lbs.) and make sure the negative battery cable plug is back in before stepping away.