2004 Chrysler PT Cruiser Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Removal - 1.6L

  1. Remove air cleaner assembly cover. See Figure.
  2. Disconnect the negative battery cable.
  3. Disconnect the electrical connector at the throttle body.
  4. Remove the purge hose from throttle body.
  5. Remove the 4 bolts from the upper to lower manifold. See Figure.
  6. Remove the 2 bolts to the upper manifold to struts. See Figure and Figure.
  7. Remove the PCV hose and the brake booster hose from the upper manifold
  8. Remove the 4 bolts from the ignition coil.
  9. Remove the spark plug cables from the ignition coil.

    Failure to route the cables properly could cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground.

    REMOVE CABLES FROM COIL FIRST.Β 

    Always remove the spark plug cable by grasping the top of the spark plug insulator, turning the boot 1/2 turn and pulling straight up in a steady motion.

  10. Remove the spark plug using a quality socket with a rubber or foam insert and special tool # 8448 on the extension to keep from damaging the spark plug tubes in the cylinder head and valve cover.
    Fig 1: Identifying Special Tool #8448
    G01858324Courtesy of DAIMLERCHRYSLER CORP.
  11. Inspect the spark plug condition.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.

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