Chrysler PT Cruiser. Manual — part 709
mineral spirits or kerosene. Inspect cylinder walls
after each 20 strokes.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marks intersect at 40-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 58).
(4)
A controlled
hone
motor
speed
between
200–300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40–60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
CLEANING
Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, (Refer to 9
- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).
(3) Examine block and cylinder bores for cracks or
fractures.
(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21°C (70°F).
The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
59) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 59). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS).
Fig. 58 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40°–60°
Fig. 59 Checking Cylinder Bore Size
9 - 116
ENGINE 2.4L DOHC
PT
ENGINE BLOCK (Continued)
CRANKSHAFT
STANDARD PROCEDURE
MEASURING CRANKSHAFT END PLAY
(1)
Mount a dial indicator to front of engine with
the locating probe on nose of crankshaft (Fig. 60).
(2)
Move crankshaft all the way to the rear of its
travel.
(3)
Zero the dial indicator.
(4)
Move crankshaft all the way to the front and
read the dial indicator. (Refer to 9 - ENGINE -
SPECIFICATIONS) for end play specification.
REMOVAL - CRANKSHAFT
NOTE: Crankshaft can not be removed when engine
is in vehicle.
(1) Remove engine assembly from vehicle (Refer to
9 - ENGINE - REMOVAL).
(2) Separate transaxle from engine.
(3) Remove drive plate/flex plate.
(4) Remove crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE
BLOCK/CRANKSHAFT
OIL
SEAL - REAR - REMOVAL).
(5) Mount engine on a suitable repair stand.
(6) Drain engine oil and remove oil filter.
(7) Remove crankshaft vibration damper (Refer to
9
-
ENGINE/ENGINE
BLOCK/VIBRATION
DAMPER - REMOVAL).
(8) Remove engine mount support bracket.
(9) Remove front timing belt covers (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(10) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(11) Remove the rear timing belt cover (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT COV-
ER(S) - REMOVAL).
(12) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(13) Remove oil pump pick-up tube.
(14) Remove the crankshaft sprocket and oil pump
(Refer to 9 - ENGINE/LUBRICATION/OIL PUMP -
REMOVAL).
(15) Remove balance shafts and housing assembly
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL).
(16) Remove crankshaft position sensor.
NOTE: If piston/connecting rod replacement is nec-
essary, remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(17) Using a permanent ink or paint marker, iden-
tify cylinder number on each connecting rod cap (Fig.
61).
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(18) Remove all connecting rod bolts and caps.
Care should be taken not to damage the fracture rod
and cap surfaces.
NOTE: Do not reuse connecting rod bolts.
(19) Remove all bed plate bolts from the engine
block (Fig. 62).
(20) Using a mallet gently tap the bedplate loose
from the engine block dowel pins.
CAUTION: Do not pry up on one side of the bed
plate. Damage may occur to cylinder block to bed
plate alignment and thrust bearing.
(21) Bed plate should be removed evenly from the
cylinder block dowel pins to prevent damage to the
dowel pins and thrust bearing.
Fig. 60 Checking Crankshaft End Play - Typical
Fig. 61 Identify Connecting Rod to Cylinder-Typical
PT
ENGINE 2.4L DOHC
9 - 117
CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
(22) Lift out crankshaft from cylinder block. Do
not damage the main bearings or journals when
removing the crankshaft.
(23) Remove the target ring mounting screws and
discard.
(24) Remove the target ring from the crankshaft.
INSPECTION
The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 63). Limits of
taper or out of round on any crankshaft journals
should be held to 0.025 mm (0.001 in.). Journal
grinding should not exceed 0.305 mm (0.012 in.)
under the standard journal diameter. DO NOT grind
thrust faces of No. 3 main bearing. DO NOT nick
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out
all passages.
CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
INSTALLATION - CRANKSHAFT
CRANKSHAFT MAIN BEARING LOCATION
CAUTION: The upper and lower thrust bearing
halves are NOT interchangeable. Make certain the
bearing half with the oil groove and hole is installed
in the engine block.
The crankshaft is supported in five main bearings.
All upper bearing shells in the crankcase have oil
grooves and holes. All lower bearing shells except
for the thrust bearing half have oil grooves and holes
(Fig. 64). Crankshaft end play is controlled by a
flanged bearing on the number three main bearing
journal.
Fig. 62 Bed Plate Bolt Removal Sequence
Fig. 63 Crankshaft Journal Measurements - Typical
Fig. 64 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
4 - LOWER THRUST BEARING PLAIN (NO OIL HOLE OR
GROOVE)
9 - 118
ENGINE 2.4L DOHC
PT
CRANKSHAFT (Continued)
(1) Install the main bearing upper shells with the
lubrication groove and oil hole in the engine block
(Fig. 65).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
CAUTION: Do not get oil on the bed plate mating
surface. It will affect the ability of the sealer to seal
the bed plate to cylinder block.
NOTE: If the crankshaft is sent out for machine
work, it must be balenced as an assembly with the
target ring installed.
(3) Clean
crankshaft
and
target
ring
with
MOPAR
t Brake Parts cleaner and dry with com-
pressed air to ensure that the crankshaft mating sur-
face and target ring mounting holes are free from oil
and lock patch debris.
NOTE: Always use NEW mounting screws whether
installing original or new target ring.
(4) Install NEWmounting screws finger tight start-
ing with the #1 location. Make sure engagment
occurs with the shoulder of the screws and mounting
hole before starting all other screws.
(5) Torque all mounting screws with T30 torx bit
to 13 Nm (110 in-lbs) following the torque sequence.
(Fig. 66)
(6) Oil the bearings and journals. Install crank-
shaft in engine block.
CAUTION: Use only the specified anaerobic sealer
on the bed plate or damage may occur to the
engine.
(7) Apply a 1.5 to 2.0 mm (0.059 to 0.078 in.) bead
of Mopar
t Bed Plate Sealant to bed plate as shown
in (Fig. 67).
(8) Install lower main bearings into main bearing
cap/bed plate. Make certain the bearing tabs are
seated into the bed plate slots. Install the main bear-
ing/bed plate into engine block.
(9) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.
Fig. 65 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
Fig. 66 Target Ring
1 - TARGET RING
Fig. 67 Bed Plate Sealing
PT
ENGINE 2.4L DOHC
9 - 119
CRANKSHAFT (Continued)
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