Chrysler PT Cruiser. Manual — part 706
• Remove turbocharger support bracket
• Remove elbow
(15) Turbocharger equipped vehicles: (Refer to
11 - EXHAUST SYSTEM/TURBOCHARGER SYS-
TEM/LINES AND HOSES - REMOVAL) (Fig. 27).
• Remove oil return tube
• Remove oil supply line
• Remove coolant supply line
• Remove coolant return line
(16) Disconnect
ignition
coil
wiring
connector.
Remove ignition coil and plug wires from engine.
(17) Disconnect camshaft position sensor wiring
connector.
(18) Remove timing belt and camshaft sprockets
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT AND SPROCKETS - REMOVAL).
(19) Remove timing belt idler pulley and rear tim-
ing belt cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - REMOVAL).
(20) Non-Turbo equipped vehicles: Remove fas-
teners securing power steering pump fluid reservoir/
bracket to cylinder head.
(21) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER - REMOVAL).
(22) Remove camshafts (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
(23) Remove rocker arms.
(24) Remove cylinder head bolts in the reverse
sequence of tightening (Fig. 33).
(25) Remove cylinder head from engine block.
(26) Inspect and clean cylinder head and block
sealing surfaces. Refer to Cleaning and Inspection in
this section for procedures.
NOTE: Ensure cylinder head bolt holes in the block
are clean, dry (free of residual oil or coolant), and
threads are not damaged.
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
Fig. 26 Turbocharger Brackets and Heat Shields
1 - UPPER/LOWER HEAT SHIELDS
2 - TURBOCHARGER SUPPORT BRACKET
3 - ELBOW
4 - ELBOW SUPPORT BRACKET
Fig. 27 Turbocharger Lines and Hoses
1 - OIL SUPPLY LINE
2 - COOLANT RETURN LINE
3 - COOLANT SUPPLY LINE
4 - OIL RETURN TUBE
9 - 104
ENGINE 2.4L DOHC
PT
CYLINDER HEAD (Continued)
INSPECTION
(1)
Cylinder head must be flat within 0.1 mm
(0.004 in.) (Fig. 28).
(2)
Inspect camshaft bearing journals for scoring.
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(4) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 29). (Refer to 9 - ENGINE - SPECIFICA-
TIONS) Replace guides if they are not within
specification.
(5) Check valve guide height (Fig. 30).
INSTALLATION - CYLINDER HEAD
NOTE: The Cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolts should be replaced (Fig. 31).
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale, the bolt should be replaced.
Fig. 28 Checking Cylinder Head Flatness
1 - FEELER GAUGE
2 - STRAIGHT EDGE
Fig. 29 Checking Wear on Valve Guide—Typical
1 - TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
Fig. 30 Valve Guide Height
1 - VALVE GUIDE
2 - 13.25 - 13.75 MM (0.521 - 0.541 IN.)
3 - SPRING SEAT
Fig. 31 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 32 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
PT
ENGINE 2.4L DOHC
9 - 105
CYLINDER HEAD (Continued)
NOTE: Head gaskets for Non-Turbo and Turbo appli-
cations are NOT interchangeable.
(1) Position the new cylinder head gasket on
engine block with the part number facing up (Fig.
32). Ensure gasket is seated over the locating dowels
in block.
(2) Position cylinder head onto engine block.
(3) Before installing the bolts, the threads should
be lightly coated with engine oil.
(4) For Non -Turbo equiped engines tighten the
cylinder head bolts in the sequence shown in (Fig.
33). Using the 4 step torque-turn method, tighten
according to the following values:
• First: All to 34 N·m (25 ft. lbs.)
• Second: All to 68 N·m (50 ft. lbs.)
• Third: All to 68 N·m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the
Fourth step.
• Fourth: Turn all bolts an additional 1/4
Turn
(5) For Turbo equiped engines tighten the cylin-
der head bolts in the sequence shown in (Fig. 33).
Using the 4 step torque-turn method, tighten accord-
ing to the following values:
• First: All to 34 N·m (25 ft. lbs.)
• Second: All to 82 N·m (60 ft. lbs.)
• Third: All to 82 N·m (60 ft. lbs.)
CAUTION: Do not use a torque wrench for the
Fourth step.
• Fourth: Turn all bolts an additional 1/4
Turn
(6) Install rocker arms and camshafts (Refer to 9 -
ENGINE/CYLINDER
HEAD/CAMSHAFT(S)
-
INSTALLATION).
(7) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER - INSTALLATION).
(8) Install rear timing belt cover and timing belt
idler pulley (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - INSTALLATION).
(9) Install camshaft sprockets and timing belt
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT AND SPROCKETS - INSTALLATION).
(10) Connect cam sensor wiring connector.
(11) Install ignition coil and plug wires. Connect
ignition coil wiring connector.
(12) Non-Turbo
equipped
vehicles:
Install
power steering pump reservoir/bracket to cylinder
head.
(13) Turbocharger equipped vehicles: (Refer to
11 - EXHAUST SYSTEM/TURBOCHARGER SYS-
TEM/LINES AND HOSES - INSTALLATION) (Fig.
27).
• Install coolant return line
• Install coolant supply line
• Install oil supply line
• Install oil return tube
(14) Turbocharger equipped vehicles: (Fig. 26)
• Install elbow
• Install turbocharger support bracket
• Install elbow support bracket
• Install turbocharger heat shields
(15) Install exhaust pipe to manifold. Tighten fas-
teners to 28 N·m (20 ft. lbs.).
(16) Install accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(17) Connect engine coolant temperature sensor
connector.
(18) Connect upper radiator hose. Connect heater
hoses to thermostat housing.
(19) Install heater tube support bracket to cylinder
head.
(20) Turbocharger equipped vehicles: Install
lower intake manifold support bracket (Fig. 25).
(21) Install fastener attaching dipstick tube to
lower intake manifold (Fig. 24) or (Fig. 25).
(22) Connect fuel supply line quick-connect at the
fuel rail assembly (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/QUICK CONNECT FITTING -
STANDARD PROCEDURE).
(23) Install upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
INSTALLATION).
(24) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(25) Connect negative cable to battery.
(26) Install clean air hose and air cleaner housing
(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER HOUSING - INSTALLATION).
Fig. 33 Cylinder Head Tightening Sequence
9 - 106
ENGINE 2.4L DOHC
PT
CYLINDER HEAD (Continued)
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 34).
(3) Remove camshaft sprockets.
(4) Remove rear timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(5) Remove
camshaft
seal
using
Special
Tool
C-4679A (Fig. 35).
CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
36).
(3) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(4) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 115
N·m (85 ft. lbs.) (Fig. 34).
(5) Install timing belt and front covers (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT
AND
SPROCKETS
-
INSTALLATION)
(Refer
to
9
-
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
Fig. 34 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 35 Camshaft Oil Seal - Removal With C-4679A
1 - SPECIAL TOOL C-4679
Fig. 36 Camshaft Seal - Installation
1 - SPECIAL TOOL MD-998306
PT
ENGINE 2.4L DOHC
9 - 107
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