Chrysler PT Cruiser. Manual — part 680
(6) Disengage and remove the PDC housing from
its mounting bracket.
(7) Remove the PDC and the engine compartment
wire harness from the engine compartment as a unit.
INSTALLATION
The Power Distribution Center (PDC) is serviced
as a unit with the engine compartment wire harness.
If any internal circuit of the PDC or the PDC hous-
ing is faulty or damaged, the entire PDC and engine
compartment wire harness unit must be replaced.
NOTE: If the power distribution center (PDC) is
being replaced with a new unit, be certain to trans-
fer each of the fuses and relays from the old power
distribution center to the proper cavities of the new
power distribution center. Refer to Wiring Diagrams
for the proper power distribution center cavity
assignments.
(1) Position the PDC in the engine compartment.
(2) Align the PDC on its mounting bracket and
install.
(3) Route the engine compartment wire harness
from the PDC through the engine compartment,
engaging each of the harness retainers to the mount-
ing provisions in the vehicle body and chassis compo-
nents.
Refer
to
Wiring
Diagrams
for
more
information on the harness routing and retainer loca-
tions.
(4) Install and tighten the fasteners that secure
each of the engine compartment wire harness ground
eyelets to the vehicle body and chassis components.
Refer to Wiring Diagrams for more information on
the ground eyelet locations.
(5) Reconnect each of the engine compartment
wire harness connectors. Refer to Wiring Diagrams
for more information on the locations of the affected
connectors.
(6) Torque nut retaining positive battery cable at
PDC to 96 - 141 N·m (85 - 130 in. lbs.).
(7) Reconnect the battery negative cable.
(8) Close hood.
(9) Verify vehicle and system operation.
RELAY
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove cover from Power Distribution Center
(PDC).
(3) Using special tool C-4817, grip the relay by the
sides and pull upward with an even effort (Fig. 7).
INSTALLATION
(1) Align relay with Power Distribution Center
(PDC) and press into position.
(2) Install cover to PDC.
(3) Connect battery negative cable.
Fig. 7 RELAY REMOVAL
1 - SPECIAL TOOL C-4817
2 - RELAY
8W - 97 - 6
8W-97 POWER DISTRIBUTION
PT
POWER DISTRIBUTION CENTER (Continued)
ENGINE
TABLE OF CONTENTS
page
page
ENGINE 1.6L SOHC . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE 2.4L DOHC . . . . . . . . . . . . . . . . . . . . . . . 74
ENGINE 1.6L SOHC
TABLE OF CONTENTS
page
page
ENGINE 1.6L SOHC
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . 6
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . 9
THREADS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FORM-IN-PLACE GASKETS AND SEALERS
ENGINE GASKET SURFACE PREPARATION
MEASURING BEARING CLEARANCE USING
PLASTIGAGE . . . . . . . . . . . . . . . . . . . . . . . . 13
ENGINE CORE AND OIL GALLERY PLUGS
INSTALLATION - ENGINE ASSEMBLY
. . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . 23
AIR CLEANER ELEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . 27
AIR CLEANER HOUSING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . 27
CYLINDER HEAD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . 29
CYLINDER HEAD COVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . 33
SPARK PLUG TUBE SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . 34
SPARK PLUG TUBE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
. . . . . . . . . . . . . . . . . . . . . . . . . 34
ROCKER ARM SHAFT / ROCKER ARM / LASH
ADJUSTER
DESCRIPTION
. . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . 36
CAMSHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . . . . . . 38
VALVE SPRINGS AND SEALS (ON VEHICLE
SERVICE)
STANDARD PROCEDURE - VALVE SPRINGS
AND SEALS (ON VEHICLE SERVICE)
VALVE SPRINGS AND SEALS (CYLINDER
HEAD REMOVED)
STANDARD PROCEDURE - VALVE SPRINGS
AND SEALS (CYLINDER HEAD REMOVED)
. . . . . . . . . . . . . . . . . . . . . . . . . . 41
INTAKE/EXHAUST VALVES & SEATS
STANDARD PROCEDURE - VALVE AND
. . . . . . . . . . . . . . . . 42
ENGINE BLOCK
. . . . . . . . . . . . . . . . . . . . . . . . . 43
PT
ENGINE
9 - 1
. . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . . . . . . 44
CRANKSHAFT MAIN BEARINGS
. . . . . . . . . . . . . . . . . . . . . . . . . 45
CRANKSHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . 45
STANDARD PROCEDURE - CRANKSHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . . . . . . . . 46
. . . . . . . . . . . . . . . . . . . . . . . . . 47
CRANKSHAFT OIL SEAL - FRONT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
. . . . . . . . . . . . . . . . . . . . . . . . . 48
CRANKSHAFT OIL SEAL - REAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
. . . . . . . . . . . . . . . . . . . . . . . . . 48
PISTON & CONNECTING ROD
. . . . . . . . . . . . . . . . . . . . . . . . . 49
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CYLINDER BORE AND PISTON - FITTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
. . . . . . . . . . . . . . . . . . . . . . . . . 51
PISTON RINGS
STANDARD PROCEDURE - PISTON RING -
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
. . . . . . . . . . . . . . . . . . . . . . . . . 52
VIBRATION DAMPER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . . . . . . . . . . . 53
ENGINE MOUNTING
. . . . . . . . . . . . . . . . . . . . . . . . . 53
TORQUE STRUTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . . . . . . 55
RIGHT ENGINE MOUNT BRACKET
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . . . . . . . 56
RIGHT MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . . . . . . . . 56
LEFT MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
. . . . . . . . . . . . . . . . . . . . . . . . . 57
LUBRICATION
. . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
OIL FILTER CARTRIDGE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
. . . . . . . . . . . . . . . . . . . . . . . . . 60
OIL FILTER CARTRIDGE HOUSING
. . . . . . . . . . . . . . . . . . . . . . . . . 61
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
. . . . . . . . . . . . . . . . . . . . . . . . . 61
OIL PAN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
. . . . . . . . . . . . . . . . . . . . . . . . . 62
OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
. . . . . . . . . . . . . . . . . . . . . . . . . 63
OIL PUMP PICK-UP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
. . . . . . . . . . . . . . . . . . . . . . . . . 63
INTAKE MANIFOLD
. . . . . . . . . . . . . . 63
. . . . . . . . . . . . . . 64
EXHAUST MANIFOLD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
. . . . . . . . . . . . . . . . . . . . . . . . . . 65
. . . . . . . . . . . . . . . . . . . . . . . . . 65
VALVE TIMING
. . . . . . . . . . . . . . . . . . . . . . . . . 66
TIMING CHAIN COVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
. . . . . . . . . . . . . . . . . . . . . . . . . 68
TIMING CHAIN/GUIDES/SPROCKETS
. . . . . . . . . . . . . . . . 69
. . . . . . . . . . . . . . 70
. . . . . . . . . . . . . . 70
. . . . . . . . . . . . . . . . 71
9 - 2
ENGINE 1.6L SOHC
PT
ENGINE 1.6L SOHC
DESCRIPTION
The 1.6 Liter (97.6 cu. in.) in-line four cylinder
engine is a single over head camshaft with four
valves per cylinder design. The engine does not have
provisions for a “free wheeling” valve train.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1–3–4–2.
The engine identification number is stamped onto
a machined pad located on the right front of the cyl-
inder block below the cylinder head sealing surface
(Fig. 1).
DIAGNOSIS AND TESTING
INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY
-
DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
• Cylinder Compression Pressure Test
• Cylinder Combustion Pressure Leakage Test
• Engine Cylinder Head Gasket Failure Diagnosis
• Lash Adjuster Noise Diagnosis
• Engine Oil Leak Inspection
Fig. 1 Engine Identification
1 - LOCATION OF V.I.N.
PT
ENGINE 1.6L SOHC
9 - 3
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст