Chrysler PT Cruiser. Manual — part 202
(3) Screw
oil
pressure
gauge
adaptor
fitting
together with seal onto timing case cover.
(4) Connect oil pressure gauge to adaptor fitting.
(5) Check oil level, adjust with correct engine oil if
necessary.
(6) Insert temperature of remote thermometer into
oil level indicator tube.
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.
CAUTION: Ensure that fan and accessory drive belt
DO NOT damage oil pressure gauge hose.
(7) Start engine and bring to operating tempera-
ture 90°C (194°F).
(8) Record engine oil pressure at idle.
(9) Raise engine speed to 3000 rpm and record oil
pressure.
(10) At normal operating temperature the oil pres-
sure must not drop below 3 bar (44 psi.). When
engine speed is raised, oil pressure must rise with
out delay and be no less than 3 bar (44 psi.) at 3000
rpm.
(11) If oil pressure is out of range, determine
cause.
REMOVAL
ENGINE COVER
(1) Remove engine cover retaining nuts (Fig. 2).
(2) Unclip engine cover from retainers and remove
engine cover from engine (Fig. 2).
ENGINE
CAUTION: WHEN REMOVING ANCILLARY COMPO-
NENTS,
PLUG ALL INLET/OUTLET AND
FLUID
LINES TO PREVENT RESIDUAL LEAKAGE AND
CONTAMINATION.
(1) Disconnect negative battery cable located under
the front passenger seat.
(2) Discharge air conditioning (Refer to 24 - HEAT-
ING & AIR CONDITIONING - STANDARD PROCE-
DURE).
(3) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(4) Remove engine cover (Refer to 9 - ENGINE
REMOVAL/ENGINE COVER - REMOVAL).
(5) Remove front grille assembly (Refer to 23 -
BODY/EXTERIOR/GRILLE - REMOVAL).
(6) Remove upper radiator closure panel (Refer to
23 - BODY/EXTERIOR/RADIATOR CROSSMEMBER
- REMOVAL).
(7) Remove air cleaner housing and air inlet hose
assembly (Refer to 9 - ENGINE/AIR CLEANER
HOUSING - REMOVAL).
(8) Remove radiator and A/C condensor (Refer to 7
- COOLING/ENGINE/RADIATOR - REMOVAL).
(9) Remove engine compartment lower silencer
and accessory drive belt splash shield.
(10) Remove power distribution center bracket.
(11) Disconnect shift cables at transaxle.
(12) Disconnect clutch hydraulic line at transaxle.
(13) Disconnect reverse light switch harness con-
nector at transaxle.
(14) Disconnect speed sensor harness connector at
transaxle.
(15) Disconnect wiring at starter and alternator,
position wiring harness aside.
(16) Disconnect three wiring harness connectors
and two ECM harness connectors, position wiring
harnesses aside.
(17) Disconnect engine coolant heater harness con-
nector.
(18) Disconnect harness connector at fuel filter/fuel
heater.
(19) Disconnect fuel lines at fuel filter/water sepa-
rator.
(20) Disconnect heater hoses at heater core.
Fig. 2 Engine Cover Mounts
1 - ENGINE COVER RETAINING NUTS
2 - ENGINE COVER
3 - ENGINE COVER MOUNTS
4 - ENGINE COVER MOUNTING STUDS
9 - 4
ENGINE
PT
ENGINE - 2.2L DIESEL (Continued)
(21) Disconnect power brake booster vacuum hose
at engine.
(22) Disconnect coolant recovery hose at engine.
(23) Disconnect coolant recovery hose at coolant
pressure recovery container.
(24) Disconnect supply hose at power steering fluid
reservoir and set aside.
(25) Disconnect vacuum hose at turbocharger.
(26) Disconnect suction line at A/C compressor and
position aside.
(27) Remove fastener retaining ground strap to
engine.
(28) Remove two fasteners from upper torque
strut.
(29) Disconnect swirl valve actuator hose at actua-
tor.
(30) Raise support vehicle.
(31) Remove front wheels.
(32) Remove two fasteners retaining left strut to
steering knuckle.
(33) Separate front strut from steering knuckle.
(34) Disengage left half shaft tripod joint from out-
put shaft.
NOTE: When removing tripod joint, DO NOT let
spline or snap ring drag across transaxle oil seal
lip.
(35) Remove left half shaft tripod joint from trans-
axle while pulling outward on top of the steering
knuckle.
(36) Support half shaft to prevent damage to seal
boot and clamp.
(37) Perform steps 34 through 38 to remove right
side tripod.
(38) Remove inner splash shield.
(39) Disconnect engine oil pressure sensor harness
connector and remove sensor from engine.
(40) Disconnect power steering pressure hose at
steering gear, position aside.
(41) Remove exhaust manifold.
(42) Remove pencil strut and lower torque strut.
(43) Remove inner cooler tube.
(44) Position the engine cradle dolly with the cra-
dle and support posts (special Tools #6710) under-
neath the engine.
(45) Carefully lower the vehicle enough to position
the engine above the support posts.
(46) Align three support posts with three engine
mounting sockets.
(47) Position the fourth support post and adaptor
underneath engine oil cooler flange.
(48) Adjust the height of each support post as nec-
essary and tighten the support posts and cradle fas-
teners.
(49) Carefully lower vehicle enough to seat engine
onto support posts.
WARNING: SAFETY STRAPS MUST BE USE TO
SECURE ENGINE TO THE DOLLY FIXTURE.
(50) Install, tighten and lock safety straps around
engine and attach them to the cradle.
(51) Raise vehicle enough to verify safety straps
retain dolly fixture to engine.
(52) Lower vehicle so that only the weight of the
engine and transmission assembly is on dolly fixture.
(53) Remove right mount through bolt.
(54) Remove two left mount through bolts.
CAUTION: IT MAY BE NECESSARY TO ADJUST THE
ENGINE AND TRANSMISSION ASSEMBLY, WITH
THE DOLLY FIXTURE ATTACHED, TO SUCCESS-
FULLY CLEAR THE ENGINE COMPARTMENT.
(55) While watching for obstructions, slowly raise
the vehicle until the engine and transmission assem-
bly clear the engine compartment.
INSTALLATION
ENGINE COVER
(1) Align engine cover with mounting studs (Fig.
2).
(2) Firmly press cover onto mounting studs (Fig.
2).
(3) Install retaining nuts at rear of engine cover
(Fig. 2).
ENGINE
WARNING: SAFETY STRAPS MUST BE USED TO
SECURE ENGINE TO THE DOLLY FIXTURE.
(1) Seat engine onto fixture support posts then
install, tighten and lock safety straps around engine,
securing it to the cradle.
(2) Position the engine and transmission assem-
blies below vehicle engine compartment.
CAUTION: IT MAY BE NECESSARY TO ADJUST THE
ENGINE AND TRANSMISSION ASSEMBLY, WITH
THE DOLLY FIXTURE ATTACHED, TO SUCCESS-
FULLY CLEAR THE ENGINE COMPARTMENT.
(3) While watching for obstructions, slowly lower
the vehicle until the engine and transmission assem-
bly clearly fit the engine compartment.
(4) Install two left mount through bolts.(Refer to 9
- ENGINE/ENGINE MOUNTING/LEFT MOUNT -
INSTALLATION).
(5) Install right mount through bolt (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
PT
ENGINE
9 - 5
ENGINE - 2.2L DIESEL (Continued)
(6) Carefully raise the vehicle enough to clear the
cradle and support post.
(7) Install charge air cooler pipe.
(8) Install pencil strut and lower torque strut
(Refer
to
9
-
ENGINE/ENGINE
MOUNTING/
TORQUE STRUT - INSTALLATION).
(9) Install exhaust manifold downpipe.
(10) Connect power steering pressure hose at
steering gear.
(11) Connect oil pressure switch electrical connec-
tor.
NOTE: When installing tripod joint, DO NOT let
spline or snap ring drag across transaxle oil seal
lip.
(12) Pull outward on the right steering knuckle
and position the right half shaft tripod joint to the
transaxle.
(13) Engage right half shaft tripod joint to output
shaft.
(14) Connect steering knuckle to strut.
(15) Install
two
fasteners
retaining
strut
to
knuckle.
(16) Perform steps 13 through 16 to install left
side tripod joint.
(17) Install front wheels.
(18) Remove cradle assembly from beneath vehicle
and lower vehicle.
(19) Connect swirl actuator line at engine.
(20) Install two fasteners for the upper torque
strut.
(21) Install ground strap.
(22) Connect suction line to A/C compressor (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C COMPRESSOR - INSTALLATION). (408)
(23) Connect vacuum hose at turbocharger.
(24) Connect power steering fluid resevoir supply
hose.
(25) Connect coolant recovery hose to recovery con-
tainer.
(26) Connect coolant recovery hose to engine.
(27) Connect power brake booster vacuum hose to
engine.
(28) Connect heater hoses to heater core (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
HEATER INLET HOSE - INSTALLATION). (400)
(29) Connect fuel lines to fuel filter/water separa-
tor.
(30) Connect harness connector to fuel filter/fuel
heater.
(31) Connect engine coolant heater harness con-
nector.
(32) Connect three wiring harness connectors and
two Engine Control Module harness connectors.
(33) Connect wiring at starter and alternator.
(34) Connect speed sensor harness connector to
transaxle.
(35) Connect reverse light switch harness connec-
tor to transaxle.
(36) Connect clutch hydraulic line at transaxle.
(37) Install power distribution center bracket.
(38) Install lower engine compartmet silencer and
accessory drive belt splash shield..
(39) Install coolant module assembly and connect
radiator fan electrical connector (Refer to 7 - COOL-
ING/ENGINE/RADIATOR - INSTALLATION).
(40) Install air cleaner inlet housing and air inlet
hose.
(41) Install upper radiator closure pane (Refer to
23 - BODY/EXTERIOR/RADIATOR CROSSMEMBER
- INSTALLATION).
(42) Install front grille assembly(Refer to 23 -
BODY/EXTERIOR/GRILLE - INSTALLATION).
(43) Refill cooling system with the appropriate
coolant mixture to the proper level (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(44) Be sure all oil and fluid levels are adjust to
specification.
(45) Connect negative battery cable.
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING)
(46) Start engine and inspect for leaks
(47) Check all fluid levels in accordance with own-
ers guide and adjust levels as necessary.
(48) Recharge air conditioning (Refer to 24 -
HEATING & AIR CONDITIONING - STANDARD
PROCEDURE).
(49) Install engine cover (Refer to 9 - ENGINE
INSTALLATION - ENGINE COVER - INSTALLA-
TION).
9 - 6
ENGINE
PT
ENGINE - 2.2L DIESEL (Continued)
SPECIFICATIONS
TORQUE
2.2L DIESEL
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Crankcase Ventilation
Screw-Air Charge
Distribution Pipe to Air
Charge Distribution Panel
11
-
97
Cylinder Head
8m-Bolt- Cylinder Head to
Timing Case Cover
20
15
-
Bolt-Front Cover to
Cylinder Head
14
-
124
12m-Bolt-Cylinder Head to
Crankcase (3 stages,
torque, torque angle,
torque angle)
60, 90°, 90°
44, 90°, 90°
-
Crankcase, Timing Case
Cover, End Cover
Bolt-Crankshaft Bearing
Cap to Crankcase (2
stages, torque, torque
angle)
55, 90°
40, 90°
-
Bolt-End Cover to
Crankcase
9
-
80
Bolt-Timing Case Cover to
Crankcase
20
15
-
Plug-Coolant Drain to
Crankcase
30
22
-
Oil Pan
6m-Bolt-Oil Pan to
Crankcase
9
-
80
8m-Bolt-Oil Pan to
Crankcase
20
15
-
Bolt-Oil Pan to End Cover
9
-
80
Bolt-Oil Pan to Timing
Case Cover
9
-
80
Bolt-Oil Pan to
Transmission Bell Housing
40
30
-
Plug-Pil Pan to Oil Drain
47
35
-
Connecting Rod
Bolt-Connecting Rod Cap
to Connecting Rod (3
stage, 1&2 torque, 3
torque angle)
5,25,90°
-
44,221, 90°
PT
ENGINE
9 - 7
ENGINE - 2.2L DIESEL (Continued)
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