Chrysler PT Cruiser. Manual — part 696
(8) Remove upper intake manifold and gasket.
LOWER INTAKE MANIFOLD
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
(2) Disconnect negative battery cable.
(3) Remove upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL).
(4) Disconnect fuel line from fuel rail.
(5) Disconnect fuel injector electrical connectors.
(6) Remove fuel rail.
(7) Remove lower intake manifold mounting bolts.
(8) Remove lower intake manifold (Fig. 104).
INSTALLATION
UPPER INTAKE MANIFOLD
(1) Position the upper intake manifold and gasket.
(2) Install
upper
intake
manifold
fasteners.
Tighten to 12 N·m (105 in. lbs.).
(3) Install upper intake manifold support bracket
fasteners (Fig. 103). Tighten M6 fasteners to 19 N·m
(165 in. lbs.) and M8 fasteners to 28 N·m (250 in.
lbs.).
(4) Connect PCV hose to upper intake manifold
(Fig. 103).
(5) Connect brake booster vacuum hose.
(6) Connect electronic throttle control motor elec-
trical connector.
(7) Connect throttle body air inlet hose and purge
solenoid vacuum hose to throttle body (Fig. 103).
(8) Connect negative battery cable.
LOWER INTAKE MANIFOLD
(1) Clean manifold sealing surfaces.
(2) Inspect and replace intake manifold seals as
necessary.
(3) Position lower intake manifold.
(4) Install lower intake manifold mounting bolts.
Tighten bolts to 26 N·m (230 in. lbs.). (Fig. 104).
(5) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(6) Insert fuel injector nozzles into openings in
lower intake manifold. Seat the injectors in place.
Install fule rail fasteners. Tighten fuel rail mounting
fasteners to 22.5 N·m ± 3 N·m (200±30 in. lbs.).
(7) Connect fuel injector electrical connectors.
(8) Connect fuel line to fuel rail.
(9) Install upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
INSTALLATION).
(10) Connect negative battery cable.
Fig. 103 Upper Intake Manifold
1 - PURGE SOLENOID VACUUM HOSE
2 - UPPER INTAKE FASTENERS
3 - PCV HOSE
4 - MANIFOLD SUPPORT BRACKET FASTENERS
Fig. 104 LOWER INTAKE MANIFOLD
1 - LOWER INTAKE MANIFOLD
2 - LOWER INTAKE MOUNTING BOLTS
9 - 64
ENGINE 1.6L SOHC
PT
INTAKE MANIFOLD (Continued)
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect ignition coil and capacitor electrical
connectors.
(3) Remove ignition coil and plug wires (Refer to 8
-
ELECTRICAL/IGNITION
CONTROL/IGNITION
COIL - REMOVAL).
(4) Raise vehicle on hoist.
(5) Disconnect exhaust pipe from exhaust mani-
fold.
(6) Remove starter heat shield bolt (Fig. 105).
(7) Lower vehicle.
(8) Remove exhaust manifold upper heat shield
bolts and remove heat shield.
(9) Remove exhaust manifold bolts and remove
manifold.
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Clean gasket surfaces.
(2) Install exhaust manifold with a new gasket
and install bolts to hold gasket in place (Fig. 106).
The gasket has tabs in the bolt holes to retain the
exhaust manifold bolts for installation purposes.
(3) Tighten the exhaust manifold bolts in a spiral
pattern starting with the center bolts and working
outward. Tighten bolts to 23 N·m (200 in. lbs.).
(4) Install exhaust manifold upper heat shield and
tighten bolts to 28 N·m (250 in. lbs.).
(5) Raise vehicle vehicle on hoist.
(6) Install the starter heat shield bolt (Fig. 105).
(7) Install the exhaust pipe to the exhaust mani-
fold. Tighten bolts to 28 N·m (250 in. lbs.).
(8) Lower vehicle.
(9) Install ignition coil and spark plug cables
(Refer to 8 - ELECTRICAL/IGNITION CONTROL/
IGNITION COIL - INSTALLATION).
(10) Connect ignition coil and capacitor electrical
connector.
(11) Connect negative battery cable.
Fig. 105 Heat Shield Bolt
Fig. 106 Exhaust Manifold, Heat Shield, and Gasket
PT
ENGINE 1.6L SOHC
9 - 65
VALVE TIMING
DESCRIPTION
The timing drive system consists of the following
(Fig. 107):
• Timing Chain
• Camshaft Sprocket
• Crankshaft Sprocket
• Right Timing Chain Guide (Movable)
• Left Timing Chain Guide (Fixed)
• Timing Chain Tensioner/Oil Reservoir Cap/Plug
with Seal Ring
The camshaft sprocket is attached to the front of
the camshaft and is used with the timing chain and
crankshaft sprocket to turn the camshaft. The cam-
shaft position sensor target is part of the sprocket
and is used with the camshaft position sensor to pro-
vide the PCM with valvetrain position information.
The timing chain tensioner is installed in the right
side of the engine block. Using engine oil pressure, the
tensioner applies constant pressure to the right side
(movable) timing chain guide, which in turn applies
pressure to the timing chain. Also as the tensioner
extends, it rachet locks in position to provide constant
timing chain tension. An oil reservoir cap attaches to
the timing chain tensioner to provide an available
“pocket” of oil to the tensioner during initial start up.
STANDARD PROCEDURE
VALVE TIMING VERIFICATION
(1) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER - REMOVAL).
(2) Remove number one spark plug.
(3) Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
(4) The mark on the camshaft sprocket should be
in line with the cylinder head cover sealing surface
(Fig. 108).
Fig. 107 Timing Drive System
1 - CAMSHAFT TIMING MARK ALIGNS WITH SINGLE PLATED/
DIMPLED LINK
2 - CAMSHAFT SPROCKET
3 - RIGHT TIMING CHAIN GUIDE (MOVABLE)
4 - LEFT TIMING CHAIN GUIDE (FIXED)
5 - PLUG WITH SEAL RING
6 - OIL RESERVOIR CAP
7 - TIMING CHAIN TENSIONER
8 - CRANKSHAFT SPROCKET
9 - TIMING CHAIN
10 - CRANKSHAFT TIMING MARKS ALIGN WITH DOUBLE
PLATED/DIMPLED LINKS
Fig. 108 Camshaft Timing Mark
1 - CYLINDER HEAD COVER SEALING SURFACE
2 - CAMSHAFT SPROCKET MARK
9 - 66
ENGINE 1.6L SOHC
PT
(5) Using a suitable light, look down into the tim-
ing chain cavity at the crankshaft sprocket. A paint
mark on the crankshaft sprocket should align with
the edge of the engine block boss indicated in (Fig.
109).
(6) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION).
TIMING CHAIN COVER
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the power steering reservior bracket
bolts (Refer to 19 - STEERING/PUMP/RESERVOIR -
REMOVAL).
(3) Partialy drain the cooling system and discon-
nect the upper radiatior hose at the radiator.
(4) Remove the radiator cooling fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(5) Raise vehicle on hoist.
(6) Remove the right front wheel.
(7) Remove the accessory drive belt splash shield.
(8) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(9) Remove the crankshaft vibration damper (Refer
to
9
-
ENGINE/ENGINE
BLOCK/VIBRATION
DAMPER - REMOVAL).
(10) Remove the accessory drive belt tensioner
(Refer to 7 - COOLING/ACCESSORY DRIVE/BELT
TENSIONERS - REMOVAL).
(11) Remove the accessory drive belt idler pulley
(Refer to 7 - COOLING/ACCESSORY DRIVE/IDLER
PULLEY - REMOVAL).
(12) Remove
the
air
conditioning
compressor
mounting bolts and position compressor out of the
way. Do Not disconnect lines from air conditioning
compressor. Support air conditioning compressor with
suitable strap.
(13) Remove the power steering pump/water pump
mounting bolts and position pump out of the way.
(14) Remove the timing cover bolts. Note the loca-
tion of the shoulder bolt(s).
(15) Remove the timing cover (Fig. 110).
Fig. 109 Crankshaft Timing Mark
1 - PAINT MARK ON CRANKSHAFT SPROCKET
2 - ENGINE BLOCK BOSS
3 - CRANKSHAFT SPROCKET
Fig. 110 Timing Chain Cover
1 - FRONT CRANKSHAFT OIL SEAL
2 - TIMING CHAIN COVER
PT
ENGINE 1.6L SOHC
9 - 67
VALVE TIMING (Continued)
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