Chrysler PT Cruiser. Manual — part 205
#8948 CHAIN SEPARATOR TOOL
#8949 THRUST PIECE
#8950 PRESSING SCREW
#8951 ASSEMBLY LINKS
9 - 16
ENGINE
PT
ENGINE - 2.2L DIESEL (Continued)
CYLINDER HEAD
STANDARD PROCEDURE
CYLINDER HEAD BOLT INSPECTION
(1) Measure cylinder head bolts between points
shown (Fig. 3).
Cylinder Head
Bolts
Thread
Diameter
12 M
Length When
New
102 mm
Maximum
Length
104 mm
(2) If the cylinder head bolt length is greater than
the maximum allowable measurement, replace the
cylinder head bolts.
MEASURE CYLINDER HEAD SURFACE
NOTE: Only resurface cylinder head contact surface
if porous or damaged. IT IS NOT necessary to
rework minor variations in flatness in the longitudi-
nal direction.
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Remove valves.
(4) Inspect cylinder head contact surface for flat-
ness, porous and damage.
(5) Using a straight edge, measure cylinder head
and cylinder block flatness.
(6) Measure cylinder head height at point (1) indi-
cated and retain reading (Fig. 4).
NOTE:
The
camshaft
housing
Must
Not
be
machined. Basic bore of the camshaft bearings will
be altered.
(7) Machine cylinder head contact surface, if nec-
essary.
(8) Measure cylinder head height (1) at point indi-
cated, record stock removal (Fig. 4).
(9) Measure valve setback at points (2) indicated
(Fig. 4).
NOTE: If measurement is less than dimension “2”
no further correct valve clearance compensation is
possible; replace valve seat ring or cylinder head if
measurement is greater than specification.
CYLINDER HEAD SPECIFICATIONS
Description
Specification
Height of Cylinder Head
(1), With Out Camshaft
Housing
126.85mm to 127.15mm
Valve Set Back (2) With
New Valves and New
Valve Seat Rings
Exhaust Valve: 1.0mm -
1.4mm
Intake Valve: 1.1mm -
1.5mm
#8952 ASSEMBLY INSERTS
Fig. 3 Measuring Cylinder Head Bolts
PT
ENGINE
9 - 17
ENGINE - 2.2L DIESEL (Continued)
REMOVAL
CYLINDER HEAD
(1) Disconnect negative battery cable located under
passenger seat (Fig. 5).
(2) Raise and support vehicle.
(3) Remove engine compartment lower silencer
and drive belt splash shield (Fig. 6).
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING COOLANT. DO NOT OPEN COOL-
ING SYSTEM UNLESS TEMPERATURE IS BELOW
90°C (194°F). OPEN CAP SLOWLY TO RELEASE
PRESSURE. STORE COOLANT IN APPROVED CON-
TAINER
ONLY.
WEAR
PROTECTIVE
GLOVES,
CLOTHING AND EYE WEAR.
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Disconnect exhaust pipe from turbocharger
downpipe.
(6) Remove exhaust manifold support bracket (Fig.
7).
(7) Remove turbocharger support bracket (Fig. 7).
(8) Disconnect charge air cooler pipe from turbo-
charger.
(9) Disconnect oil return line from turbocharger.
(10) Remove starter and position out of the way.
(11) Remove accessory drive belt.
(12) Lower vehicle.
(13) Remove front grille assembly (Refer to 23 -
BODY/EXTERIOR/GRILLE - REMOVAL).
(14) Remove radiator closure panel (Refer to 23 -
BODY/EXTERIOR/RADIATOR
CROSSMEMBER
-
REMOVAL).
(15) Disconnect upper radiator hose from thermo-
stat housing.
(16) Pull cooling module forward to gain access to
the intake manifold inlet hose. Disconnect inlet hose
at manifold (Fig. 8).
(17) Remove engine cover. (Refer to 9 - ENGINE
COVER- REMOVAL).
Fig. 4 Cylinder Head Measurments
1 - CYLINDER HEAD HEIGHT
2 - VALVE SETBACK
Fig. 5 Battery Location
1 - BATTERY
2 - PASSENGER SEAT
Fig. 6 Engine Compartment Lower Silencer
1 - ENGINE COMPARTMENT SILENCER
2 - ACCESSORY DRIVE BELT SPLASH SHIELD
9 - 18
ENGINE
PT
CYLINDER HEAD (Continued)
(18) Remove air cleaner housing and turbocharger
inlet hose (Fig. 9)(Refer to 9 - ENGINE/AIR INTAKE
SYSTEM/AIR CLEANER HOUSING - REMOVAL).
(19) Remove coolant recovery pressure container-
.(Refer
to
7
-
COOLING/ENGINE/COOLANT
RECOVERY PRESS CONTAINER - REMOVAL)
(20) Disconnect
vacuum
hose
at
turbocharger
waste gate actuator.
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
RISK OF POISONING FROM INHALING AND SWAL-
LOWING FUEL. RISK OF INJURY FROM SKIN AND
EYE CONTACT WITH FUEL. POUR FUELS ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS.
WEAR
PROTECTIVE
CLOTHING
WHEN HANDLING FUEL.
(21) Disconnect fuel injector, glow plug, and cam-
shaft position sensor electrical connectors
(22) Remove fuel high pressure lines, return lines,
injectors, and fuel rail(Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/FUEL INJECTOR - REMOVAL).
(23) Reposition wiring harness out of way.
(24) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(25) Position piston of cylinder #1 to ignition TDC.
Fig. 7 Turbo Support Bracket
1 - TURBO SUPPORT BRACKET
2 - EXHAUST MANIFOLD SUPPORT BRACKET
3 - EXHAUST MANIFOLD
4 - TURBOCHARGER
5 - TURBO OUTLET PIPE
Fig. 8 IntakeManifold
1 - INTAKE MANIFOLD
2 - INTAKE MANIFOLD RETAINING BOLTS
3 - INTAKE INLET HOSE
Fig. 9 Turbocharger Inlet Hose
1 - TURBOCHARGER INLET HOSE
2 - TURBOCHARGER
PT
ENGINE
9 - 19
CYLINDER HEAD (Continued)
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