Chrysler PT Cruiser. Manual — part 201
11.0
CHARTS AND GRAPHS
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CHARTS AND GRAPHS
ENGINE
TABLE OF CONTENTS
page
page
ENGINE - 2.2L DIESEL
. . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . 13
CYLINDER HEAD
. . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . 21
CYLINDER HEAD COVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . 24
VALVE SPRINGS
. . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . 26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CAMSHAFT(S)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . 28
ENGINE BLOCK
GALLERY PLUGS . . . . . . . . . . . . . . . . . . . . . 30
CRANKSHAFT
JOURNALS . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . 32
CRANKSHAFT OIL SEAL - REAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . 33
VACUUM PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . 34
OIL PRESSURE SENSOR/SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OIL PAN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . 36
OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . 37
OIL JET
. . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . 37
BALANCE SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . . . . . . 38
TIMING CHAIN COVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . . . . . . 40
TIMING CHAIN
. . . . . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . . . 42
. . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . 46
. . . . . . . . . . . . . . . . . 46
. . . . . . . . . . . . . . . . . . . . . . . 47
TIMING CHAIN TENSIONER
PT
ENGINE
9 - 1
INTAKE MANIFOLD
. . . . . . . . . . . . . . . . . . . . . . . . . 51
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
. . . . . . . . . . . . . . . . . . . . . . . . . . 52
. . . . . . . . . . . . . . . . . . . . . . . . . 52
AIR CLEANER ELEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . . . . . . . . . . . 53
AIR CLEANER HOUSING
. . . . . . . . . . . . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . . . . . . . . . 54
ENGINE MOUNTING
. . . . . . . . . . . . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . . . . . . . . . . . . . 55
TORQUE STRUT
. . . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ENGINE TORQUE STRUT ADJUSTMENT
RIGHT MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
. . . . . . . . . . . . . . . . . . . . . . . . . 57
LEFT MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . 58
ENGINE - 2.2L DIESEL
DESCRIPTION
This 2.2 Liter four-cylinder Common Rail Diesel
Injection (CDI) engine is an in-line overhead valve
diesel engine (Fig. 1). This engine utilizes a cast iron
cylinder block and an aluminum cylinder head. The
engine is turbocharged and intercooled. This engine
also has four valve per cylinder and dual overhead
camshafts (Fig. 1).
DESCRIPTION
SPECIFICATION
Engine
2.2L CDI
Engine Description
4 Cylinder In-Line Engine
With 4-Valve Technology
Fuel Injection System
Common Rail Diesel
Injection (CDI)
Fuel
Diesel
Rated Output
85/4200 kW at RPM
Torque
250/1400-2600 Nm at
RPM
Maximum Speed
4600 RPM
Compression Ratio
18:0
Bore/Stroke
88.0/88.3 mm
Eff. Displacement
2148 cm3
STANDARD PROCEDURE
COMPRESSION TESTING ENGINE
(1) Warm up engine to operating temperature
(approximately 80 °C, 176°F).
(2) Shut off engine.
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(5) Crank engine several times with the starter to
eliminate combustion residues in the cylinders.
(6) Insert compression tester adapter with check
valve installed into glow plug hole of cylinder to be
tested.
(7) Test compression pressure by cranking engine
with starter for at least 8 revolutions.
Fig. 1 2.2L Diesel Engine
9 - 2
ENGINE
PT
(8) Carry out test procedure at the remaining cyl-
inders in the same way.
(9) Compare pressure readings obtained with the
specified pressures. If the pressure reading is below
the minimum compression pressure or if the permis-
sible difference between the individual cylinders is
exceeded. Refer to (Refer to 9 - ENGINE - STAN-
DARD PROCEDURE).
2.2L
COMPRESSION SPECIFICATION
Minimum Allowable
18 bar (261 psi.)
Maximum Allowable
Difference Between
Cylinders
3 bar (44 psi.)
Average Compression
Ratio
24 - 30 bar (348 - 435
psi)
(10) Remove compression tester and adapter from
cylinder head.
(11) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).
(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
CYLINDER LEAK DOWN TEST
(1) Warm engine to operating temperature.
WARNING:
DO
NOT
OPEN
COOLING
SYSTEM
UNLESS COOLANT TEMPERATURE IS BELOW 90C
(194°F). RISK OF INJURY TO SKIN AND EYES AS A
RESULT
OF
SCALDING
WITH
HOT
COOLANT
WHICH
SPLASHES
OUT.
RISK
OF
POISONING
FROM
SWALLOWING
COOLANT.
OPEN
CAP
SLOWLY AND RELEASE PRESSURE. STORE COOL-
ANT IN PROPER CONTAINERS ONLY. WEAR PRO-
TECTIVE
GLOVES,
CLOTHING
AND
EYE
PROTECTION.
NOTE: Turn cap carefully as far as first detent,
release pressure, then unscrew cap.
(2) Open cooling system cap at coolant recover
pressure container.
(3) Remove engine cover.(Refer to 9 - ENGINE -
REMOVAL).
(4) Unscrew oil filler cap.
(5) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
NOTE: Crank engine at crankshaft in direction of
rotation of the engine (clockwise).
(6) Position cylinder to be tested to ignition Top
Dead Center (DTC).
NOTE: Calibrate cylinder leak down tester and
remove check valve in screw-in fitting.
(7) Connect cylinder leak down tester and follow
INSPECTING Instruction.
INSPECTING
NOTE: If crankshaft rotates, install retaining lock for
crankshaft/ring gear.
(1) Pressurize cylinder with compressed air and
read off pressure loss at cylinder leak tester. If exces-
sive pressure loss exists, determine cause by viewing
the paragraph below.
NOTE: If the retaining lock is installed, remove it,
rotate engine and install lock once again.
(2) Carry out test of other cylinders in the firing
order of engine.
DETERMINING PRESSURE LOSS
If a great pressure loss was detected, listen using a
stethoscope around suspected areas, such as the cyl-
inder head gasket through the air suction area, the
exhaust system, the oil filler neck, the pre-chamber,
the bore wholes of the cylinder effected or neighbor-
ing cylinders. Observe the coolant in the expansion
tank, looking for traces of bubbles.
The possible causes of pressure loss are:
• If air leak is detected through the prechamber,
cylinder bore hole, from a neighboring cylinder or air
bubbles in the coolant expansion tank, pressure loss
may be caused by the cylinder head gasket.
• If the air leak occurs in the air suction area, the
pressure loss may be caused by the intake valve(s).
• Air leak through the exhaust system, may be
caused by the exhaust valve(s).
• Air leak through the oil filler neck, may be
caused by piston, ring, or cylinder sleeve.
If none of the above evidence supports a failure,
the engine may be assembled and run until operating
temperature is reached. Reconnect engine leak down
tester on a warm engine with a few drops of clean
engine oil in the cylinder being tested. Engine oil
seals the clearance between the piston and cylinder
for a short length of time. If under this condition a
smaller pressure loss occurs for a shorter length of
time, it is possible that the cause is piston, ring or
cylinder sleeve related.
CHECKING OIL PRESSURE
(1) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(2) Remove oil galley plug together with seal at
timing case cover.
PT
ENGINE
9 - 3
ENGINE - 2.2L DIESEL (Continued)
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