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Home >> Chrysler >> 2006 >> PT Cruiser Base, 2D Convertible, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 2.4L DOHC Engine >> Manifold-Intake >> Installation >> Upper Intake Manifold >> Turbo

Upper Intake Manifold: Turbo

Fig 1: Covering Lower Intake Manifold Openings
GC0042858Courtesy of DAIMLERCHRYSLER CORP.
1 - INTAKE MANIFOLD MUST BE COVERED DURING SERVICE
  1. If lower intake manifold was covered during service, remove cover (1). See Fig 1.
  2. Clean all sealing surfaces. Replace upper intake manifold gasket.
    Fig 2: Intake Manifold Tightening Sequence - 2.4L Turbo
    GC0021602Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: This engine could be equipped with either a plastic intake manifold or an aluminum intake manifold.
  3. Position upper intake manifold on lower intake manifold. On engines equipped with an aluminum intake manifold, tighten manifold fasteners to 28 N.m (250 in. lbs.) in sequence shown. See Fig 2. On engines equipped with a plastic intake manifold, tighten manifold fasteners to 12 N.m (105 in. lbs.) in sequence shown. See Fig 2.
    Fig 3: Intake Manifold Support
    GC0021598Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTAKE MANIFOLD SUPPORT BRACKET
  4. Install upper intake manifold to cylinder head support bracket (1). See Figure. Torque cylinder head fasteners to 28 N.m (250 in. lbs.) and manifold fasteners to 6 N.m (55 in. lbs.).
    Fig 4: INTAKE COVER
    GC0042859Courtesy of DAIMLERCHRYSLER CORP.
    1 - Item_1
    2 - Item _2
  5. Install the intake manifold cover (1).
    Fig 5: Proportional Purge Hoses
    GC0042862Courtesy of DAIMLERCHRYSLER CORP.
    1 - PROPORTIONAL PURGE HOSES
  6. Connect purge solenoid hose to throttle body (1). See Fig 5.
    Fig 6: Throttle Cables - 2.4L Turbo
    GC0042866Courtesy of DAIMLERCHRYSLER CORP.
  7. Connect brake booster vacuum hose and PCV hose to intake manifold.
  8. Install the 2 screws for the throttle cable bracket and tighten to 12 N.m (105 in. lbs.) on aluminum intake manifolds and 6 N.m (55 in. lbs.) on plastic intake manifolds.
    Fig 7: Throttle Control Shield 2.4L Turbo
    GC0042868Courtesy of DAIMLERCHRYSLER CORP.
  9. Install the throttle control shield. See Fig 7.
  10. Connect idle air control (IAC) motor and throttle position sensor connectors.
    Fig 8: MAP Sensor - 2.4L Turbo
    GC0042870Courtesy of DAIMLERCHRYSLER CORP.
    1 - MAP SENSOR
  11. Connect the MAP sensor (1) connector. See Fig 8.
    Fig 9: Charge Air Cooler Hoses
    GC0042869Courtesy of DAIMLERCHRYSLER CORP.
    1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY
    2 - CHARGE AIR COOLER
    3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
  12. Connect charge air cooler hose to throttle body (1). See Fig 9. Tighten hose clamp to 1.7 N.m (15 in. lbs.).
  13. Connect negative battery cable.
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