Chrysler PT Cruiser. Manual — part 684
(42)
Remove right mount through bolt (Fig. 11)
and left mount attaching bolts (Fig. 12).
(43) Continue raising vehicle slowly until engine/
transaxle assembly clears engine compartment. It
may be necessary to move the engine/transmission
assembly with the cradle to allow for removal around
body flanges.
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine/transaxle assembly.
(2) Continue lowering vehicle until engine/trans-
axle aligns to mounting locations. Install mounting
bolts at the right and left engine/transaxle mounts
(Fig. 11) and (Fig. 12). Tighten bolts to 118 N·m (87
ft. lbs.).
(3) Install the upper engine torque strut (Fig. 11).
(4) Remove safety straps from engine/transaxle
assembly. Slowly raise vehicle enough to remove the
engine dolly and cradle.
(5) Raise vehicle.
(6) Install A/C compressor mounting bolts. Recon-
nect A/C compressor electrical connectors.
(7) Connect power steering pressure line to power
steering pump.
Fig. 11 Engine Mounting - Right Side
1 - BOLTS
2 - RIGHT FENDER
3 - UPPER TORQUE STRUT BRACKET
4 - NUTS
5 - BOLT
6 - UPPER TORQUE STRUT
7 - ENGINE MOUNT BRACKET
8 - BOLT
9 - LOWER TORQUE STRUT
10 - BOLT
11 - RIGHT ENGINE MOUNT
Fig. 12 Left Mount Bolts
1 - BOLT
2 - TRANSAXLE
3 - LEFT MOUNT
9 - 16
ENGINE 1.6L SOHC
PT
ENGINE 1.6L SOHC (Continued)
(8) Install fasteners securing clutch slave cylinder
and damper (Fig. 10).
(9) Connect exhaust pipe to exhaust manifold.
Install fasteners and torque to 28 N·m (250 in. lbs.).
(10) Install left and right drive axles (Refer to 3 -
DIFFERENTIAL & DRIVELINE/HALF SHAFT -
INSTALLATION).
(11) Install pencil strut and lower torque strut
(Fig. 9).
(12) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELT
-
INSTALLATION).
(13) Install accessory drive belt splash shield.
(14) Install both front wheels.
(15) Lower vehicle.
(16) Connect fuel line to fuel rail.
(17) Connect power steering reservoir hose to
power steering pump. Install fastener securing power
steering return line to right engine bracket. Install
fasteners securing power steering reservoir bracket
to right engine bracket.
(18) Connect ground strap to cylinder head.
(19) Connect brake booster and purge solenoid vac-
uum hoses.
(20) Connect transmission shift cables and trans-
mission electrical connectors.
(21) Install cooling module assembly (fan, radiator,
A/C condenser). Connect radiator fan electrical con-
nector.
(22) Connect A/C lines at junction near upper
torque strut.
(23) Connect upper A/C line to A/C condenser.
(24) Connect upper and lower radiator hoses.
(25) Install upper radiator crossmember (Refer to
23 - BODY/EXTERIOR/RADIATOR CROSSMEMBER
- INSTALLATION).
(26) Connect heater hoses to thermostat housing
and heater return tube.
(27) Connect coolant recovery container hose to
radiator neck.
(28) Install bolts attaching Power Distribution
Center (PDC). Connect positive cable to PDC and
ground wire to vehicle body (Fig. 8).
(29) Connect engine wiring harness at Powertrain
Control Module (PCM).
(30) Install battery tray and battery (Fig. 6) and
(Fig. 7). Connect positive battery cable.
(31) Connect negative battery cable.
(32) Install air cleaner housing and throttle body
air inlet hose.
(33) Install new oil filter. Fill engine crankcase
with proper oil to correct level.
(34) Fill power steering system.
(35) Fill Cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(36) Evacuate and recharge A/C system (Refer to
24 - HEATING & AIR CONDITIONING - STAN-
DARD PROCEDURE).
(37) Start engine and run until operating temper-
ature is reached.
(38) Perform torque strut adjustment procedure
(Refer
to
9
-
ENGINE/ENGINE
MOUNTING/
TORQUE STRUT - ADJUSTMENTS).
(39) Adjust transmission linkage, if necessary.
Fig. 13 Positioning Engine - Removal/Installation
1 - SAFETY STRAPS
2 - SPECIAL TOOL 6710
3 - WOODEN BLOCK
4 - SPECIAL TOOL 6848
5 - PLACE REAR POSTS INTO LOCATING HOLES
PT
ENGINE 1.6L SOHC
9 - 17
ENGINE 1.6L SOHC (Continued)
SPECIFICATIONS
1.6L SOHC ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Type
In-Line OHV, SOHC
Number of
Cylinders
4
Compression
Ratio
10.5:1
Firing Order
1-3-4-2
Max. Variation
Between
Cylinders
25%
Metric
Standard
Displacement
1.6 Liters
97.6 cu. in.
Bore
77.0 mm
3.03 in.
Stroke
85.8 mm
3.377 in.
Compression
Pressure
1172-1551 kPa
170-225 psi
ENGINE BLOCK
DESCRIPTION
SPECIFICATION
Metric
Standard
Cylinder Bore
Diameter
76.9924-
77.0076 mm
3.031-3.0317 in.
Out-of-Round
(Max.)
0.0076 mm
0.0002 in.
Taper (Max.)
0.051 mm
0.002 in.
PISTONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Piston Diameter
76.956-76.974
mm
3.029-3.030 in.
Clearance @
40.25 mm (1.58
in.) from top of
piston
0.018-0.52 mm
0.0008-0.0020 in.
Weight
219-224 grams
7.5-8.8 oz.
Land Clearance
(Diametrical)
0.758-0.790 mm
0.0299-0.0312 in.
Piston Length
46.25 mm
1.82 in.
Piston Pin Hole
Diameter
19.008-19.015
mm
.748-.750 in.
Piston Ring
Groove Width -
Top
Compression
Ring
1.215-1.235 mm
0.0478-0.0486 in.
Piston Ring
Groove Width -
2nd
Compression
Ring
1.215-1.235 mm
0.0478-0.0486 in.
Piston Ring
Groove Width -
Oil Ring
2.521-2.541 mm
0.0993-0.1000 in.
PISTON PINS
DESCRIPTION
SPECIFICATION
Metric
Standard
Clearance in
Piston
0.008-0.015 mm
0.0003-0.0006 in.
Clearance in
Connecting Rod
Interference
Diameter
18.995-19.000
mm
0.7478-0.7480 in.
End Play
None
Length
56.50-57.00 mm
2.224-2.2244 in.
9 - 18
ENGINE 1.6L SOHC
PT
ENGINE 1.6L SOHC (Continued)
PISTON RINGS
DESCRIPTION
SPECIFICATION
Metric
Standard
Ring Gap-Top
Compression
Ring
0.20-0.36 mm
0.007-0.014 in.
Wear Limit
0.8 mm
0.031 in.
Ring Gap-2nd
Compression
Ring
0.25-0.46 mm
0.009-0.018 in.
Wear Limit
1.0 mm
0.039 in.
Ring Gap-Oil
Control Steel
Rails
0.20-0.58 mm
0.0078-0.0228
in.
Wear Limit
1.0 mm
0.039 in.
Ring Side
Clearance-
Compression
Rings
0.025-0.065
mm
0.0010-0.0026
in.
Wear Limit
0.10 mm
0.004 in.
Ring Side
Clearance-Oil
Ring Pack
0.004-0.178
mm
0.0002-0.0070
in.
Ring Width-
Compression
Rings
1.17-1.19 mm
0.046-0.047 in.
Ring Width-Oil
Ring Pack
2.354-2.517
mm
0.093-0.099 in.
CONNECTING ROD
DESCRIPTION
SPECIFICATION
Metric
Standard
Bearing
Clearance
0.023-0.067
mm
0.0009-0.0026
in.
Wear Limit
0.075 mm
0.003 in.
Bore Diameter-
Piston Pin End
18.96-18.98
mm
0.746-0.747 in.
Bore Diameter-
Crankshaft End
47.005-46.991
mm
1.8505-1.8500
in.
Connecting Rod
- Length
135.6 mm
5.34 in.
Connecting Rod
- Weight (less
bearing)
241.32 grams
8.51 oz.
Side Clearance
0.13-0.38 mm
0.005-0.015 in.
Wear Limit
0.40 mm
0.016 in.
CRANKSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Connecting Rod
Journal
Diameter
43.992-44.008
mm
1.731-1.732 in.
Main Bearing
Journal
Diameter
47.922-48.008
mm
1.731-1.890 in.
Journal
Out-of-Round
(Max.)
0.006 mm
0.0002 in.
Journal Taper
(Max.)
0.008 mm
0.0003 in.
End Play
0.09-0.24 mm
0.0035-0.0094
in.
Wear Limit
0.37 mm
0.015 in.
Main Bearing
Clearance
0.022-0.062
mm
0.0008-0.0024
in.
Connecting Rod
Bearing
Clearance
0.023-0.067
mm
0.0009-0.0026
in.
ROCKER ARM SHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Rocker Arm
Shaft Diameter
18.966-18.984
mm
0.7466-0.7474
in.
PT
ENGINE 1.6L SOHC
9 - 19
ENGINE 1.6L SOHC (Continued)
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