Cleaning; Inspection; Installation - Chrysler PT Cruiser Service & Repair Manual

9 - 64 ENGINE 1.6L SOHC
INTAKE MANIFOLD (Continued)
(4) Install lower intake manifold mounting bolts.
Tighten bolts to 26 N·m (230 in. lbs.). (Fig. 104).
(5) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(6) Insert fuel injector nozzles into openings in
lower intake manifold. Seat the injectors in place.
Install fule rail fasteners. Tighten fuel rail mounting
fasteners to 22.5 N·m ± 3 N·m (200±30 in. lbs.).
(7) Connect fuel injector electrical connectors.
(8) Connect fuel line to fuel rail.
(9) Install upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE

INSTALLATION).

(10) Connect negative battery cable.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect ignition coil and capacitor electrical
connectors.
(3) Remove ignition coil and plug wires (Refer to 8
- ELECTRICAL/IGNITION
COIL - REMOVAL).
(4) Raise vehicle on hoist.
(5) Disconnect exhaust pipe from exhaust mani-
fold.
(6) Remove starter heat shield bolt (Fig. 105).
Fig. 105 Heat Shield Bolt
(7) Lower vehicle.
(8) Remove exhaust manifold upper heat shield
bolts and remove heat shield.
(9) Remove exhaust manifold bolts and remove
manifold.
MANIFOLD -
CONTROL/IGNITION

CLEANING

(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.

INSPECTION

(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Clean gasket surfaces.
(2) Install exhaust manifold with a new gasket
and install bolts to hold gasket in place (Fig. 106).
The gasket has tabs in the bolt holes to retain the
exhaust manifold bolts for installation purposes.
Fig. 106 Exhaust Manifold, Heat Shield, and Gasket
(3) Tighten the exhaust manifold bolts in a spiral
pattern starting with the center bolts and working
outward. Tighten bolts to 23 N·m (200 in. lbs.).
(4) Install exhaust manifold upper heat shield and
tighten bolts to 28 N·m (250 in. lbs.).
(5) Raise vehicle vehicle on hoist.
(6) Install the starter heat shield bolt (Fig. 105).
(7) Install the exhaust pipe to the exhaust mani-
fold. Tighten bolts to 28 N·m (250 in. lbs.).
(8) Lower vehicle.
PT