Chrysler PT Cruiser. Manual — part 211
(2) Align drill holes at end of balance shafts with
assembly point of carrier halves (Fig. 42).
(3) Position balance shaft assembly on engine
block and install retaining bolts. Tighten bolts to
25N·m, then to 45N·m.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Install engine compartment lower silencer and
accessory drive belt splash shield (Fig. 37).
(6) Lower vehicle.
(7) Refill engine oil and power steering fluid to
proper specifications.
(8) Connect negative battery cable.
TIMING CHAIN COVER
REMOVAL
The engine must be removed from the vehicle to
remove the timing chain cover.
WARNING:
DO
NOT
OPEN
COOLING
SYSTEM
UNLESS TEMPERATURE IS BELOW 90°C (194°F).
OPEN CAP SLOWLY TO RELEASE PRESSURE.
STORE
COOLANT
IN
APPROVED
CONTAINER
ONLY. RISK OF INJURY TO SKIN AND EYES FROM
SCALDING
COOLANT.
WEAR
PROTECTIVE
GLOVES, CLOTHING AND EYE WEAR.
(1) Disconnect negative battery cable.
(2) Drain coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Remove engine (Refer to 9 - ENGINE -
REMOVAL).
(5) Support engine on suitable engine stand.
(6) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
NOTE: Rotate engine on crankshaft. DO NOT crank
the engine at the bolt of the camshaft sprocket.
NOTE: DO NOT crank engine back.
(7) Position piston of cylinder #1 to ignition TDC.
Markings on the camshaft bearing cap must be
aligned.
(8) Install retaining lock for crankshaft/starter
ring gear.
(9) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - REMOVAL)
(10) Remove cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(11) Remove vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)..
(12) Drain engine oil.
NOTE: Remove the bolts in area of timing chain
cover. Loosen all other oil pan bolts.
(13) Remove oil pan bolts.
(14) Remove M8 bolts of cylinder head on timing
chain cover.
(15) Remove timing case cover retaining bolts and
remove cover from engine (Fig. 43).
(16) Remove
remaining
ancillary
components
attached to the timing chain cover.
INSTALLATION
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during assembly.
(1) Inspect cylinder head gasket and oil pan gas-
ket. If damaged, replace.
(2) Replace front crankshaft seal (Refer to 9 -
ENGINE/ENGINE
BLOCK/CRANKSHAFT
OIL
SEAL - FRONT - INSTALLATION).
(3) Install ancillary components to timing case
cover.
(4) Apply sealant to the marked surfaces with a
bead thickness of 1.5 ± 0.5 mm (Fig. 44).
Fig. 42 Balance Shaft Position Before Installation
1 - BALANCE SHAFT ASSEMBLY
2 - DRILL HOLES IN END OF BALANCE SHAFTS
3 - ASSEMBLY POINT OF CARRIER HALVES
9 - 40
ENGINE
PT
BALANCE SHAFT (Continued)
NOTE: Install timing cover within 10 minutes after
applying sealant. Do not spread sealant bead.
NOTE: Do not seal pressurized oil galleries to the
crankcase.
Sealant
applied
at
these
points
is
entrained by the oil flow and blocks the oil supply
passages.
(5) Position and install timing case cover. Tighten
bolts to 20 N·m (177 lbs in).
(6) Install M8 bolts of cylinder head on timing case
cover. Tighten bolts to 20 N·m (177 lbs in).
(7) Position and install the oil pan. Tighten M6
bolts to 9 N·m (80 lbs in) and M8 bolts to 20 N·m
(177 lbs in).
(8) Install
vibration
damper/crankshaft
pulley.
Tighten M8.8 bolt in two stages, 200N·m (147 lbs ft.)
then 90°, M10.9 bolt 325N·m (240 lbs ft) then 90°.
(9) Install cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
(10) Install timing chain tensioner with new seal
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS
-
INSTALLA-
TION).
(11) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION).
(12) Remove retaining lock for crankshaft/starter
ring gear.
(13) Install engine (Refer to 9 - ENGINE -
INSTALLATION).
(14) Fill coolant to the proper level, with the
proper coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(15) Tighten oil drain plug to 30N·m (265 lbs in).
(16) Fill crankcase with the correct oil, to the
proper level. Refer to owners manual for specifica-
tions.
(17) Connect negative battery cable.
WARNING: (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION - STANDARD PROCEDURE)
(18) Start engine and inspect for leaks.
(19) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
Fig. 43 Timing Chain Cover
1 - INTERMEDIATE GEAR
2 - TIMING CHAIN COVER
3 - TENSIONING RAIL
4 - BEARING PIN
5 - OIL PAN
Fig. 44 Timing Chain Cover Sealing Surface
1 - TIMING CHAIN COVER
2 - SEALANT BEAD
PT
ENGINE
9 - 41
TIMING CHAIN COVER (Continued)
TIMING CHAIN
REMOVAL
BOTTOM GUIDE RAIL
The engine must be removed to service the bottom
guide rail.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Drain coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(4) Remove engine (Refer to 9 - ENGINE -
REMOVAL).
(5) Support engine on suitable engine stand.
(6) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL)
(7) Remove cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
NOTE: Oil pan DOES NOT need to be removed.
Remove bolts in the area of timing case cover then
loosen the remaining bolts.
NOTE: Remove timing case cover carefully. Care
must be taken not to damage oil pan gasket.
(8) Remove timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Remove guide rail from bearing pin (Fig. 45).
INTERMEDIATE GEAR
(1) Disconnect negative battery cable located under
the passenger seat.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(4) Remove the intermediate gear cover (Fig. 47).
NOTE: Rotate engine on crankshaft. DO NOT rotate
the engine using the camshaft sprocket bolt.
NOTE: DO NOT rotate the engine backwards.
(5) Position piston of cylinder #1 to ignition TDC.
Markings on the camshaft bearing cap must be
aligned.
(6) Install special tool #8933, crankshaft lock (Fig.
46).
Fig. 45 Bottom Guide Rail
1 - TIMING CHAIN COVER
2 - BOTTOM SLIDE RAIL
3 - BEARING PIN
4 - OIL PAN
Fig. 46 8933-Crankshaft Lock
1 - ENGINE BLOCK
2 - SPECIAL TOOL #8933
9 - 42
ENGINE
PT
(7) Install special tool #8929, camshaft locking pin
through first camshaft bearing cap into hole in the
inlet camshaft sprocket to lock inlet camshaft (Fig.
47).
(8) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - REMOVAL).
(9) Remove cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(10) Remove top slide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(11) Mark camshaft sprocket relative to timing
chain.
(12) Unbolt camshaft sprocket from exhaust cam-
shaft.
NOTE: Note position of dowel pin for camshaft
sprocket alignment during reassembly.
(13) Secure camshaft sprocket to timing chain with
tie strap.
(14) Remove camshaft sprocket.
(15) Remove intermediate gear and bushing (Fig.
48).
TIMING CHAIN TENSIONING RAIL
(1) Disconnect negative battery cable.
(2) Remove cylinder head cover.
(3) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
NOTE: Oil pan DOES NOT need to be removed.
Remove bolts in the area of timing case cover then
loosen the remaining bolts.
NOTE: Remove timing case cover carefully. Care
must be taken not to damage oil pan gasket.
Fig. 47 Special Tool 8929-Camshaft Locking Pin
1 - SPECIAL TOOL #8929
2 - INTAKE CAM SPROCKET
3 - INTERMEDIATE GEAR COVER
Fig. 48 Intermediate Gear
1 - CAMSHAFT SPROCKET BOLTS
2 - INTAKE CAMSHAFT
3 - DOWEL PIN
4 - INTERMEDIATE GEAR BUSHING
5 - INTERMEDIATE GEAR
6 - CAMSHAFT LOCKING PIN
7 - INTAKE CAMSHAFT SPROCKET
PT
ENGINE
9 - 43
TIMING CHAIN (Continued)
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