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Chrysler PT Cruiser. Manual - part 214

(19) Remove remaining intake manifold retaining

bolts and remove manifold from engine (Fig. 69).

CLEANING

(1) Discard gasket(s).
(2) Clean all sealing surfaces.

INSPECTION

(1) Inspect

manifold

for

cracks

distortion.

Replace manifold if necessary.

(2) Inspect manifold for gasket surface damage or

warpage. Replace manifold if necessary.

INSTALLATION

(1) Clean gaskets/seals mating surfaces.
(2) Install new intake manifold seals on intake

manifold (Fig. 70).

(3) Place intake on cylinder head and install

retaining bolts (Fig. 69). Be sure to install high
pressure fuel line brackets in proper position
(Fig. 68). Torque bolts to 20N·m (14.7 lbs.ft.).

(4) Connect air inlet hose at intake manifold (Fig.

69).

(5) Connect swirl valve actuator hose at actuator

(Fig. 68).

(6) Lower radiator and cooling fan assembly in

vehicle. Attach charge air cooler to radiator.

(7) Attach A/C condenser to radiator with retain-

ing screws.

(8) Connect both A/C lines at condenser.
(9) Raise vehicle on hoist.
(10) Connect cooling fan electrical connector.
(11) Connect lower radiator hose at radiator.
(12) Lower vehicle.
(13) Connect upper radiator hose at radiator.
(14) Install radiator closure panel (Refer to 23 -

BODY/EXTERIOR/RADIATOR

CROSSMEMBER

INSTALLATION).

(15) Install front grille assembly (Refer to 23 -

BODY/EXTERIOR/GRILLE - INSTALLATION).

(16) Refill cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(17) Evacuate and recharge air conditioning sys-

tem (Refer to 24 - HEATING & AIR CONDITION-
ING - STANDARD PROCEDURE).

(18) Install engine cover (Refer to 9 - ENGINE -

INSTALLATION).

(19) Connect negative battery cable.

Fig. 69 Intake Manifold

1 - INTAKE MANIFOLD
2 - INTAKE MANIFOLD RETAINING BOLTS
3 - INTAKE INLET HOSE

Fig. 70 Intake Manifold Seals

1 - INTAKE MANIFOLD
2 - INTAKE MANIFOLD SEALS

9 - 52

ENGINE

INTAKE MANIFOLD (Continued)

AIR CLEANER ELEMENT

REMOVAL

(1) Unfasten clasps on sides of air cleaner housing

cover. Lift cover off air cleaner housing (Fig. 71).

(2) Remove filter element.
(3) If necessary, clean the inside of the air cleaner

housing.

INSTALLATION

(1) Install new filter element.
(2) Place cover over air cleaner housing. Snap

clasps in place.

AIR CLEANER HOUSING

DESCRIPTION

The air cleaner housing attaches to the inner

fender in front of the left side strut tower (Fig. 72).
An ambient air duct supplies underhood air for the
engine. It attaches to the lower air cleaner box.

REMOVAL

AIR CLEANER HOUSING

(1) Disconnect

turbocharger

inlet

hose

air

cleaner (Fig. 72).

(2) Pull air cleaner housing straight up to remove

(Fig. 72).

(3) Remove the inlet duct from the air cleaner

housing (Fig. 72).

Fig. 71 Air Cleaner Cover - Typical

Fig. 72 Air Cleaner Housing Assembly

1 - TURBOCHARGER INLET HOSE
2 - MAF SENSOR RETAINING BOLT
3 - MAF SENSOR
4 - O-RING
5 - MAF SENSOR ELECTRICAL CONNECTOR
6 - AIR CLEANER ASSEMBLY
7 - INLET DUCT
8 - AIR CLEANER HOUSING ASSEMBLY BRACKET

ENGINE

9 - 53

REMOVAL

(1) Remove engine cover (Refer to 9 - ENGINE

COVER - REMOVAL).

(2) Disconnect turbocharger inlet hose at MAF

sensor (Fig. 73).

(3) Disconnect turbocharger inlet hose at turbo-

charger and remove inlet tube (Fig. 74).

INSTALLATION

AIR CLEANER HOUSING

Make sure that the rubber grommets, for the lower

pins, are in place when reinstalling the air cleaner
housing (Fig. 72). The rubber grommet for the PDC
bracket must be installed also.

(1) Install air inlet duct into air cleaner housing

(Fig. 72).

(2) Lower air cleaner housing assembly into engine

compartment and align studs at bottom of housing
with bracket. Push housing assembly down until
fully seated in bracket (Fig. 72).

(3) Connect turbocharger inlet hose to air cleaner

assembly (Fig. 72).

INSTALLATION

(1) Connect turbocharger inlet hose at turbo-

charger (Fig. 74).

(2) Connect turbocharger inlet hose at MAF sensor

(Fig. 73).

(3) Install engine cover (Refer to 9 - ENGINE

COVER - INSTALLATION).

ENGINE MOUNTING

DESCRIPTION

The engine mounting system consists of a four-

point system utilizing two load-carrying mounts and
two torque struts. The load-carrying mounts are
located on each frame rail. The right mount is a
hydro-elastic mount and left mount is a conventional
elastomeric isolator. The two torque controlling struts
are attached at the front of the engine, straddling the
right side load-carrying mount. The upper strut con-
nects to the suspension strut tower and the lower to
the suspension crossmember.

Fig. 73 Air Cleaner Housing Assembly

Fig. 74 Turbocharger Inlet Hose

1 - TURBOCHARGER INLET HOSE
2 - TURBOCHARGER

9 - 54

ENGINE

AIR CLEANER HOUSING (Continued)

OPERATION

The four-point engine mounting system minimizes

the transmission of structure-borne engine noise to
the passenger compartment. The load-carrying right
and left mounts dampen and isolate vertical motion
and vibration. The two struts absorbs torque reaction
forces and torsional vibrations.

TORQUE STRUT

REMOVAL

REMOVAL - UPPER

(1) Remove bolts attaching upper torque strut to

shock tower bracket and engine mount bracket (Fig.
75).

(2) Remove the upper torque strut.

REMOVAL - LOWER

(1) Raise vehicle on hoist.
(2) Remove accessory drive belt splash shield (Fig.

76).

(3) Remove pencil strut (Fig. 77).
(4) Remove bolts attaching lower torque strut to

crossmember and strut bracket (Fig. 77).

(5) Remove lower torque strut.

INSTALLATION

UPPER

(1) Position the upper torque strut into mounting

location (Fig. 75).

(2) Install the torque strut mounting bolts and

perform the torque strut adjustment procedure (Refer
to

ENGINE/ENGINE

MOUNTING/TORQUE

STRUT - ADJUSTMENTS).

LOWER

(1) Position lower torque strut into mounting loca-

tions.

(2) Install mounting bolts and perform torque

strut adjustment procedure (Refer to 9 - ENGINE/
ENGINE MOUNTING/TORQUE STRUT - ADJUST-
MENTS).

(3) Install pencil strut and tighten nuts to 58 N·m

(43 ft. lbs.) (Fig. 77).

Fig. 75 Engine Mounting - Right Side

1 - BOLT
2 - RIGHT FENDER
3 - UPPER TORQUE STRUT BRACKET
4 - NUTS
5 - BOLT

6 - UPPER TORQUE STRUT
7 - BOLT
8 - LOWER TORQUE STRUT
9 - BOLT
10 - RIGHT ENGINE MOUNT

ENGINE

9 - 55

ENGINE MOUNTING (Continued)

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