Chrysler PT Cruiser. Manual — part 207
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Remove high pressure fuel lines to injectors
(Fig. 16).
(4) Disconnect fuel injector, camshaft position sen-
sor, fuel pressor sensor, fuel pressure solenoid, and
glow plug electrical connectors.
(5) Disconnect injector drain tubes at injectors.
(6) Disconnect fuel rail return line to pump at rail.
(7) Remove engine harness retaining bolts and
reposition harness out of way.
(8) Remove fuel injectors (Refer to 14 - FUEL SYS-
TEM/FUEL
INJECTION/FUEL
INJECTOR
-
REMOVAL).
(9) Detach hose from oil separator.
(10) Remove cylinder head cover retaining bolts
and remove cover (Fig. 17).
INSTALLATION
(1) Install new gasket and injector bore seals on
cylinder head cover (Fig. 18).
NOTE: Do not tighten cylinder head cover bolts
until injectors are installed.
Fig. 16 Fuel Injector and Glow Plug Locations
1 - FUEL INJECTORS
2 - GLOW PLUGS
3 - FUEL RAIL
4 - HIGH PRESSURE FUEL LINE
Fig. 17 Cylinder Head Cover - Typical
1 - CAMSHAFT POSITION (CMP) SENSOR
2 - CYLINDER HEAD COVER
3 - CYLINDER HEAD COVER GASKET
4 - INJECTOR BORE SEALS
Fig. 18 Cylinder Head Cover Gasket and Seal
Location
1 - CYLINDER HEAD COVER
2 - CYLINDER HEAD COVER GASKET
3 - INJECTOR BORE SEALS
9 - 24
ENGINE
PT
(2) Position cylinder head cover with new gasket
and seals. Tighten bolts only finger tight.
(3) Install injectors into cylinder head (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).
(4) Torque cylinder head cover bolts to 9N·m (80
lbs. in.).
(5) Reroute engine harness and install retaining
bolts.
(6) Install injector high pressure fuel lines.
(7) Torque injector retaining bolts to 7N·m (62 lbs.
in.) + 90°.
(8) Connect fuel injector, camshaft position sensor,
fuel pressure sensor, fuel pressure solenoid, and glow
plug electrical connectors.
(9) Connect fuel drain tubes at injectors.
(10) Attach oil seperator hose.
(11) Connect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN ENGINE
IS OPERATING. DO NOT STAND IN A DIRECT LINE
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(12) Start engine and inspect for leaks.
(13) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
VALVE SPRINGS
REMOVAL
VALVE SPRINGS
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(4) Remove injectors (Refer to 14 - FUEL SYS-
TEM/FUEL
INJECTION/FUEL
INJECTOR
-
REMOVAL).
(5) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(6) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - REMOVAL).
(7) Remove front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - REMOVAL).
(8) Remove top guide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(9) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: The timing chain must be held in up position
so as not to jam during procedure.
(10) Position piston of cylinder to be processed to
DTC by rotating the crankshaft clockwise. DO NOT
crank engine. DO NOT rotate engine backward.
(11) Install crankshaft lock, special tool #8933.
(12) Seal injector hole with connection piece and
retain with orginal tensioning claw.
(13) Connect cylinder leak tester with adaptors
and pressurize the cylinder to 5 bar (73 psi.).
WARNING: Valve springs and retainers must be
kept in order of the cylinder they were removed.
NOTE:
Using
tool,
screw
retaining
fork
into
threaded edge of cylinder head and position thrust
piece vertically at top of valve spring retainer.
(14) Compress valve spring.
(15) Remove valve keepers.
(16) Remove top valve spring retainer and valve
spring.
(17) Remove valve stem seals.
(18) Remove bottom valve spring retainer.
NOTE: Inspect all cylinder head components for
wear or damage.
(19) Repeat procedure for each cylinder as neces-
sary.
VALVES
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
WARNING: Suitably mark the valve and the position
in the cylinder head before removal. Failure to do
so will result in improperly seated valves and pos-
sible engine damage after reassembly.
NOTE:
Using
tool,
screw
retaining
fork
into
threaded edge of cylinder head and position thrust
piece vertically at top of valve spring retainer.
(4) Using a suitable valve spring compressor, com-
press valve spring.
(5) Remove valve keepers.
(6) Remove top valve spring retainer and valve
spring.
(7) Remove valve stem seals.
(8) Repeat steps 5 through 9 for each valve as nec-
essary.
PT
ENGINE
9 - 25
CYLINDER HEAD COVER (Continued)
(9) Remove cylinder head from assembly board.
WARNING: Valves, springs and retainers must be
kept in order of the cylinder they were removed.
(10) Remove valves.
INSTALLATION
VALVE SPRINGS
NOTE: Inspect all valve springs and retainers for
wear or damage. Replace as necessary.
(1) Position piston of cylinder to be processed to
TDC by rotating the crankshaft clockwise. DO NOT
crank engine or rotate engine counter clock-
wise.
(2) Connect cylinder leak tester with adaptors and
pressurize the cylinder to 5 bar (73 psi).
(3) Install lower valve spring retainer.
(4) Install valve stem seal.
(5) Install valve spring.
(6) Install valve spring retainer.
NOTE:
Using
tool,
screw
retaining
fork
into
threaded edge of cylinder head and position thrust
piece vertically at the top of each valve spring
retainer.
NOTE: Ensure that the valve keepers are seated
properly.
(7) Compress valve and install valve keepers.
(8) Repeat procedure for each cylinder as neces-
sary.
(9) Remove special tooling from cylinder head.
(10) Position piston of #1 cylinder to ignition TDC.
(11) Install camshafts and check basic position
(Refer to 9 - ENGINE/CYLINDER HEAD/CAM-
SHAFT(S) - INSTALLATION).
(12) Install top guide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(13) Install front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - INSTALLATION).
(14) Install timing chain tensioner with new gas-
ket (Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(15) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION).
(16) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).
WARNING: SERVICE VEHICLES IN A WELL VENTI-
LATED AREA AND AVOID IGNITION SORCES. RISK
OF INJURY TO SKIN AND EYES FROM FUEL JET
FLOWING OUT.
(17) Install injectors (Refer to 14 - FUEL SYS-
TEM/FUEL
INJECTION/FUEL
INJECTOR
-
INSTALLATION).
(18) Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(19) Start the engine and inspect for leaks.
(20) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
VALVES
WARNING: Valves must be kept in their original
positions in cylinder head. Failure to do so will
result in engine damage.
NOTE: Inspect all valves, springs and retainers for
wear or damage. Replace as necessary.
(1) Install valves in their original position in the
cylinder head.
(2) Install lower valve spring retainer.
(3) Install valve stem seal.
(4) Install valve spring.
(5) Install valve spring retainer.
NOTE:
Using
tool,
screw
retaining
fork
into
threaded edge of cylinder head and position thrust
piece vertically at the top of each valve spring
retainer.
NOTE: Ensure that the valve keepers are seated
properly.
(6) Using a suitable valve spring compressor, com-
press valve spring and install valve keepers.
(7) Repeat steps 3 through 7 for each valve as nec-
essary.
(8) Remove valve assembly from cylinder head.
(9) Install cylinder head on engine block (Refer to
9 - ENGINE/CYLINDER HEAD - INSTALLATION).
(10) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).
(11) Connect negative battery cable.
9 - 26
ENGINE
PT
VALVE SPRINGS (Continued)
WARNING: US EXTREME CAUTION WHEN THE
ENGINE IS IN OPERATION. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(12) Start engine and check for leaks.
(13) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
CAMSHAFT(S)
STANDARD PROCEDURE
CHECKING CAMSHAFT POSITION
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
WARNING: NO FIRE, SPARKS, OR SMOKING. RISK
OF POISONING FROM INHALING AND SWALLOW-
ING FUEL AS WELL AS RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUEL ONLY INTO SUITABLE AND MARKED CON-
TAINERS. WEAR PROTECTIVE CLOTHING WHEN
HANDLING FUEL.
(3) Remove injectors (Refer to 14 - FUEL SYS-
TEM/FUEL
INJECTION/FUEL
INJECTOR
-
REMOVAL).
(4) Clean injectors and recesses(Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
(5) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
NOTE: Rotate engine at crankshaft only. DO NOT
crank engine at the camshaft and DO NOT rotate
the engine backward.
(6) Position piston of cylinder #1 to ignition TDC.
(7) Insert the locking pin (special tool #8929)
through first camshaft bearing cap into the hole in
the left inlet camshaft sprocket (Fig. 19).
NOTE: The two markings in the inlet camshaft
sprockets must be positioned opposite and mark-
ings of camshaft and camshaft bearing cap must be
aligned. If not, perform basic position of camshafts.
(8) Remove locking pin from camshaft bearing cap
hole.
(9) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION).
(10) Install injectors (Refer to 14 - FUEL SYS-
TEM/FUEL
INJECTION/FUEL
INJECTOR
-
INSTALLATION).
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NO WEAR LOOSE CLOTHING.
(11) Start the engine and inspect for leaks.
Fig. 19 Checking Camshaft Position - Typical
1 - CAMSHAFT SPROCKET ALIGNMENT DOTS
2 - CAMSHAFT LOCK POSITION
3 - INTAKE CAMSHAFT SPROCKET
4 - CAMSHAFT AND BEARING CAP ALIGNMENT MARKS
5 - CAMSHAFT LOCKING PIN (SPECIAL TOOL #8929)
6 - INTAKE CAMSHAFT SPROCKET
PT
ENGINE
9 - 27
VALVE SPRINGS (Continued)
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