Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHRYSLER2004PT CRUISER TOURING, 2.4 B, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 101 (2.7L)INTAKE MANIFOLDINTAKE MANIFOLD - UPPERINSTALLATION

2004 Chrysler PT Cruiser Touring, 2.4 B, Automatic

Intake Manifold - Upper: Installation

2004 Chrysler PT Cruiser Touring, 2.4 B, AutomaticSECTION Installation

WARNING: This page is about a different car, the 2003 Dodge Intrepid, 2003 Chrysler Intrepid, and 2003 Chrysler Concorde. However, it is still accessible from the selected car via links, so may be relevant.

Clean and inspect sealing surfaces. Gaskets can be reused, if free of cuts or tears.
NOTE: Make sure fuel injectors and wiring harnesses are in correct position to not interfere with upper manifold installation.
Position upper manifold onto lower manifold (Figure).
Install manifold attaching bolts and tighten in sequence shown in (Fig 1) to 12 N.m (105 in. lbs.).

Fig 1: Tightening Upper Intake Manifold Bolts In Sequence

Courtesy of DAIMLERCHRYSLER CORP.

Tighten upper fastener at throttle body support bracket.
Connect speed control servo, PCV (Figure), brake booster, and vapor purge hoses.
Connect electrical connectors to the following components:
- Manifold Absolute Pressure (MAP) Sensor
- Throttle Position Sensor (TPS) Sensor
- Idle Air Control (IAC) Motor
Install throttle cable bracket.
Connect throttle and speed control cables to bracket and throttle arm.
Install air inlet resonator and inlet tube. Connect Inlet Air Temperature (IAT) Sensor connector.
Connect negative cable to battery remote jumper terminal.

RENDER: 1.0x

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When to See a Mechanic

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

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