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Home >> Chrysler >> 2006 >> PT Cruiser Base, 2D Convertible, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 59 (2.4L Engine (Service Information)) >> Manifolds >> Manifold-Exhaust >> Installation >> Exhaust Manifold

Exhaust Manifold

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The exhaust manifold on Turbocharged equipped vehicles is serviced as an assembly with the Turbocharger. Refer to INSTALLATION .
Fig 1: Exhaust Manifold Tightening Sequence
GC0021275Courtesy of CHRYSLER LLC
  1. Install a new exhaust manifold gasket. DO NOT APPLY SEALER  .
  2. Position exhaust manifold in place. Tighten fasteners in the sequence shown above to 23 N.m (200 in. lbs.). See Fig 1. Raise and lower vehicle for fastener access as necessary. Repeat tightening procedure until all fasteners are at specified torque.
    Fig 2: Exhaust Manifold Heat Shields
    GC0042889Courtesy of CHRYSLER LLC
    1 - UPPER HEAT SHIELD
    2 - LOWER HEAT SHIELD
  3. Install exhaust manifold heat shields. See Fig 2. Tighten bolts to 12 N.m (105 in. lbs.).
    Fig 3: Exhaust Manifold Support Bracket
    GC0042892Courtesy of CHRYSLER LLC
  4. Install exhaust manifold support bracket. See Fig 3.
  5. Install engine wiring heat shield. See Figure.
  6. Connect oxygen sensor electrical connector.
    Fig 4: Exhaust Manifold To Pipe Connection
    GC0042891Courtesy of CHRYSLER LLC
    1 - GASKET
    2 - CATALYTIC CONVERTER
    3 - NUT
  7. Install exhaust pipe (2) to manifold with a new gasket (1). See Fig 4. Tighten fasteners to 28 N.m (250 in. lbs.).
  8. Install coolant recovery container. Refer to INSTALLATION .
    Fig 5: Power Steering Fluid Reservoir
    GC0042894Courtesy of CHRYSLER LLC
    1 - POWER STEERING FLUID RESERVOIR
    2 - RETAINING TAB
  9. Install fasteners securing power steering fluid reservoir (1) to cylinder head.
    Fig 6: MAP Sensor
    GC0042895Courtesy of CHRYSLER LLC
    1 - MAP SENSOR
  10. Connect MAP sensor (1) electrical connector.
    Fig 7: Throttle Cables - 2.4L Turbo
    GC0042896Courtesy of CHRYSLER LLC
  11. Connect throttle and speed control cables to the throttle lever and bracket.
    Fig 8: Air Inlet System - 2.4L Turbo
    GC0042897Courtesy of CHRYSLER LLC
    1 - CLEAN AIR HOSE
    2 - AIR CLEANER HOUSING
    3 - FRESH AIR INLET DUCT
    4 - PDC MOUNTING BRACKET
  12. Connect negative cable to battery.
  13. Install clean air hose (1) and air cleaner housing (2).
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