Spark Plug Removal Removal - 1.6L; Removal - 2.0/2.4L; Removal - 2.4L Turbo; Installation - 1.6L - Chrysler PT Cruiser Service & Repair Manual

PT
SPARK PLUG
REMOVAL
REMOVAL - 1.6L
(1) Remove air cleaner assembly cover (Fig. 11).
(2) Disconnect the negative battery cable.
(3) Disconnect the electrical connector at the throt-
tle body.
(4) Remove the purge hose from throttle body.
(5) Remove the 4 bolts from the upper to lower
manifold (Fig. 12).
(6) Remove the 2 bolts to the upper manifold to
struts (Fig. 13) and (Fig. 14).
(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.
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
(Fig. 29) on the extension to keep from damaging the
spark plug tubes in the cylinder head and valve
cover.
Fig. 29 SPECIAL TOOL # 8448
(11) Inspect the spark plug condition.
IGNITION CONTROL

REMOVAL - 2.0/2.4L

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.
NOTE: REMOVE cables from coil first before remov-
ing spark plug insulator.
Special care should be used when installing spark
plugs in the 2.4L cylinder head spark plug wells. Be
sure the plugs do not drop into the wells, damage to
the electrodes can occur.
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap. Overtightening can
also damage the cylinder head.
(1) Remove the air cleaner lid, disconnect the inlet
air sensor and makeup air hose.
(2) Disconnect the negative battery cable.
(3) Remove the upper intake manifold, refer to the
Engine section for more information.
(4) Disconnect the cable from the ignition coil first.
Always remove the spark plug cable by grasping
the top of the spark plug insulator, rotate the boot
90° and pulling straight up in a steady motion.
(5) Remove the spark plug using a quality socket
with a rubber or foam insert.
(6) Inspect the spark plug condition.

REMOVAL - 2.4L TURBO

Special care should be used when installing spark
plugs in the 2.4L cylinder head spark plug wells. Be
sure the plugs do not drop into the wells, damage to
the electrodes can occur.
NOTE: REMOVE cables from the coil first before
removing spark plug insulator.
(1) Disconnect the negative battery cable.
(2) Unlock and disconnect the MAP sensor electri-
cal connector.
(3) Remove the throttle control shield.
(4) Disconnect the cable from the ignition coil first.
Always remove the spark plug insulator, rotate the
boot 90° and pulling straight up in a steady motion.
(5) Remove the spark plug using a quality socket
with a rubber or foam insert (Fig. 30).
(6) Inspect the spark plug condition.
INSTALLATION

INSTALLATION - 1.6L

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.
8I - 13