Chrysler PT Cruiser. Manual — part 687
(17) Lower vehicle.
(18) Remove upper torque strut.
(19) Remove
fastener
securing
power
steering
return line to right engine mount bracket.
(20) Remove fasteners securing power steering res-
ervoir to right engine mount bracket.
(21) Support engine with floor jack and wooden
block on oil pan.
(22) Remove right engine mount through bolt.
(23) Jack up engine. Remove remaining fasteners
holding right engine mount bracket. Remove right
engine mount bracket.
(24) Remove camshaft position sensor.
(25) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(26) Rotate crankshaft until triangular timing
mark on camshaft sprocket is at the 12 o’clock posi-
tion.
(27) For reassembly purposes, paint the timing
chain link that lines up with camshaft timing mark
(Fig. 16).
(28) Using Special Tool 8435 to hold camshaft
sprocket, remove camshaft sprocket bolt (Fig. 17).
(29) Remove the timing chain tensioner plug from
engine block. Remove oil reservoir cap and timing
chain tensioner (Fig. 18).
NOTE: The design of the timing chain cover will
allow the timing chain to stay on the crankshaft
sprocket without skipping any teeth. Do not rotate
engine.
(30) Remove camshaft sprocket from camshaft.
Partially lower camshaft sprocket to allow timing
chain to be removed from camshaft sprocket. Allow
timing chain to fall into crankcase.
Fig. 16 Identify Timing Chain Link for Reassembly
Purposes
1 - PAINT THE LINK THAT ALIGNS WITH TIMING MARK
2 - CAMSHAFT SPROCKET TIMING MARK
Fig. 17 Special Tool 8435 - Camshaft Sprocket
Holding Wrench
1 - SPECIAL TOOL 8435
Fig. 18 Timing Chain Tensioner
1 - PLUG WITH SEAL RING
2 - OIL RESERVOIR CAP
3 - TIMING CHAIN TENSIONER
9 - 28
ENGINE 1.6L SOHC
PT
CYLINDER HEAD (Continued)
(31) Remove cylinder head plugs. Remove fasten-
ers holding timing chain guides to cylinder head.
Remove timing chain guides (Fig. 19).
CAUTION: Avoid damaging spark plug tubes when
removing cylinder head bolts.
(32) Remove cylinder head bolts (Fig. 20).
(33) Remove cylinder head and gasket.
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.
INSPECTION
(1)
Cylinder head must be flat within 0.1 mm
(0.004 in.) (Fig. 21).
(2)
Inspect camshaft bearing journals for scoring.
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
Fig. 19 Timing Chain Guide Mounting
1 - RIGHT TIMING CHAIN GUIDE (MOVABLE)
2 - LEFT TIMING CHAIN GUIDE (FIXED)
3 - FASTENER(S)
4 - CYLINDER HEAD PLUG(S)
Fig. 20 Cylinder Head and Gasket
1 - M10 CYLINDER HEAD BOLT (QTY 10)
2 - CYLINDER HEAD GASKET
3 - CYLINDER HEAD
4 - M8 CYLINDER HEAD BOLT (QTY 2)
Fig. 21 Checking Cylinder Head Flatness
1 - FEELER GAUGE
2 - STRAIGHT EDGE
PT
ENGINE 1.6L SOHC
9 - 29
CYLINDER HEAD (Continued)
(4) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 22). (Refer to 9 - ENGINE - SPECIFICA-
TIONS). Replace cylinder head if they are not within
specification.
INSTALLATION - CYLINDER HEAD
NOTE: The cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolt(s) should be replaced (Fig. 23).
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(s) should be
replaced.
(1) Clean the cylinder head and cylinder block
sealing surfaces (Refer to 9 - ENGINE/CYLINDER
HEAD - CLEANING).
(2) Position a new cylinder head gasket on the
locating dowels.
(3) Position the cylinder head onto the engine
block. Make sure the cylinder head seats fully over
the locating dowels.
CAUTION: Avoid damaging spark plug tubes when
installing/torquing cylinder head bolts.
(4) Before
installing
cylinder
head
bolts,
the
threads should be oiled with engine oil.
(5) Tighten the cylinder head bolts in the sequence
shown in (Fig. 24). Using the 4 step torque method,
tighten according to the following values:
Step One:
• Tighten the ten M10 bolts to 20 N·m (15 ft. lbs.)
• Tighten the two M8 bolts to 15 N·m (11 ft. lbs.)
Step Two:
• Tighten the ten M10 bolts to 41 N·m (30 ft. lbs.)
Step Three:
• Recheck the ten M10 bolts to 41 N·m (30 ft. lbs.)
Step Four:
• Do not use a torque wrench for this step.
Tighten the ten M10 bolts an additional 90 degrees
• Tighten the two M8 bolts to 30 N·m (22 ft. lbs.)
(6) Install timing chain guides. Torque fasteners to
28 N·m (250 in. lbs.) (Fig. 19).
(7) Retrieve timing chain from crankcase with a
magnet or fabricated hook.
(8) Align triangular timing mark on cam sprocket
with the timing chain link that was painted during
disassembly. Install timing chain on cam sprocket
(Fig. 16).
(9) Install camshaft sprocket on the camshaft.
CAUTION: Do Not use an impact wrench for tight-
ening the camshaft sprocket bolt. Damage to the
camshaft timing pin can result. Use a hand wrench
only.
(10) Install camshaft sprocket bolt. While holding
the camshaft sprocket with Special Tool 8435, torque
bolt to 115 N·m (85 ft. lbs.) (Fig. 17).
Fig. 22 Checking Wear on Valve Guide—Typical
1 - TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
Fig. 23 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. 24 Cylinder Head Bolt Tightening Sequence
9 - 30
ENGINE 1.6L SOHC
PT
CYLINDER HEAD (Continued)
(11) Reset the timing chain tensioner using the fol-
lowing method:
(a) Remove oil reservoir cap from timing chain
tensioner (Fig. 25).
(b) Place tensioner on a clean flat surface.
(c) Place your palm against the tensioner and
press down on the tensioner with continuous pres-
sure until the fully extended tensioner bottoms out
(Fig. 26).
(d) Install oil reservoir cap onto timing chain
tensioner (Fig. 25).
(12) Install timing chain tensioner with oil reser-
voir cap into engine block (Fig. 18).
(13) Install timing chain tensioner plug with seal
ring. Torque plug to 62 N·m (46 ft. lbs.).
CAUTION: Do not pry directly on chain. Damage to
timing chain may occur.
(14) Using a long thin screwdriver, pry in on the
right (movable) timing chain guide until the timing
chain tensioner rachets out to tension the chain (Fig.
27).
NOTE: Ensure the timing chain is properly posi-
tioned within the channel of the timing chain
guides.
(15) Install cylinder head plugs. Torque to 18 N·m
(162 in. lbs.) (Fig. 19).
(16) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION).
Fig. 25 Timing Chain Tensioner/Oil Reservoir
Cap/Plug
1 - CHECK BALL
2 - PLUG WITH SEAL RING
3 - OIL RESERVOIR CAP
4 - TIMING CHAIN TENSIONER
Fig. 26 Resetting Timing Chain Tensioner
Fig. 27 Timing Chain Tensioner Activation
PT
ENGINE 1.6L SOHC
9 - 31
CYLINDER HEAD (Continued)
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