Chrysler PT Cruiser. Manual — part 689
(9) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION).
(10) Install upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
INSTALLATION).
(11) Connect negative battery cable.
ROCKER ARM SHAFT /
ROCKER ARM / LASH
ADJUSTER
DESCRIPTION
The two rocker shafts are mounted to the top of
the camshaft bearing caps. The left rocker shaft
holds the eight roller rocker arms for the intake
valves, while the right rocker shaft holds the four
forked roller rocker arms for the exhaust valves. The
roller rocker arms are mounted to rocker shafts and
are positioned over the camshaft and valve stems.
The rocker shaft is installed through the center of
the roller rocker arms, which allows the roller rocker
arms to pivot. The valve stem end of the roller rocker
arms contain a hydraulic lash adjuster. The hydrau-
lic lash adjuster, using oil pressure, constantly main-
tains the correct clearance between the rocker arm
and camshaft/valve stem. The camshaft end of the
roller rocker arm contains a roller that rides on the
lobe of the camshaft. Roller rocker arms provide the
camshaft with a quiet, low-friction means of opening
the valves. Hydraulic lash adjusters are replaced as
an assembly with the rocker arms (Fig. 39).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER - REMOVAL).
NOTE: Use the following procedure to remove both
the intake and exhaust rocker shafts.
CAUTION: To avoid damage to the rocker shafts,
loosen each rocker shaft/camshaft bearing cap bolt
one turn at a time in the following sequence:
(3) Loosen the rocker shaft/camshaft bearing cap
bolts starting with the center bolt and working
toward the ends.
(4) Remove the rocker shafts/roller rocker arm
assemblies (Fig. 39).
NOTE: Hydraulic lash adjusters are replaced as an
assembly with the rocker arms.
INSTALLATION
(1) Lubricate the roller portion of the rocker arms
with clean engine oil.
(2) Install
the
rocker
shaft/roller
rocker
arm
assemblies on the camshaft bearing caps, camshaft,
and valve stems (Fig. 39).
(3) Hand start rocker shaft/camshaft bearing cap
bolts.
NOTE: When tightening the rocker shaft/camshaft
bearing cap bolts, ensure the camshaft bearing
caps are fully seated and the roller rocker arms
remain seated in their proper position.
Fig. 39 Rocker Arm Shafts/Lash Adjusters/Camshaft
1 - EXHAUST VALVE ROCKER ARM
2 - INTAKE VALVE ROCKER ARM SPACER
3 - INTAKE VALVE ROCKER SHAFT
4 - INTAKE VALVE ROCKER ARM
5 - CAMSHAFT
6 - CAMSHAFT BEARING CAP
7 - EXHAUST VALVE ROCKER SHAFT
9 - 36
ENGINE 1.6L SOHC
PT
SPARK PLUG TUBE (Continued)
(4) Tighten the rocker shaft/camshaft bearing cap
bolts gradually in the sequence shown in (Fig. 40).
Final torque all bolts to 25 N·m (225 in. lbs.).
(5) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER - INSTALLATION).
(6) Connect negative battery cable.
CAMSHAFT
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER - REMOVAL).
(3) Disconnect camshaft position sensor connector.
Remove camshaft position sensor.
(4) Rotate crankshaft until number one cylinder is
at TDC on compression stroke.
(5) Using Special Tool 8435 to hold camshaft
sprocket, remove camshaft sprocket bolt (Fig. 41).
(6) Install Special Tool 8446 as shown in (Fig. 42).
Hold tool against camshaft and tighten tool mounting
bolts.
(7) Slide camshaft sprocket onto Special Tool 8446
(Fig. 42).
NOTE: Use the following procedure to remove both
the intake and exhaust rocker shafts.
CAUTION: To avoid damage to the rocker shafts,
loosen each rocker shaft/camshaft bearing cap bolt
one turn at a time in the following sequence:
(8) Loosen the rocker shaft/camshaft bearing cap
bolts starting with the center bolt and working
toward the ends.
Fig. 40 Rocker Arm Shaft Tightening Sequence
Fig. 41 Special Tool 8435 - Camshaft Sprocket
Holding Wrench
1 - SPECIAL TOOL 8435
Fig. 42 Special Tool 8446 - Camshaft Sprocket
Holder
1 - SPECIAL TOOL 8446
PT
ENGINE 1.6L SOHC
9 - 37
ROCKER ARM SHAFT / ROCKER ARM / LASH ADJUSTER (Continued)
(9) Remove the rocker shafts/roller rocker arm
assemblies (Fig. 43).
(10) Remove camshaft bearing caps noting orienta-
tion and numbering for reassembly purposes (Fig.
43).
(11) Lift camshaft from cylinder head (Fig. 43).
INSPECTION
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 44). If journals are binding, check
the cylinder head for damage. Also check cylinder
head oil holes for clogging.
(2) Check the cam lobe and bearing surfaces for
abnormal wear and damage. Replace camshaft if
defective.
(3) Inspect camshaft bearing caps for abnormal
wear and damage.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the rocker arms.
(4) Measure the lobe actual wear (unworn area -
wear zone = actual wear) (Fig. 44) and replace cam-
shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wear limit is 0.254 mm (0.010 in.).
INSTALLATION
(1) Lubricate the camshaft bearing journals with
clean engine oil.
(2) Install
the
camshaft
with
the
camshaft
sprocket alignment pin in the 12 o’clock position.
(3) Install the camshaft bearing caps in their
proper position (Fig. 43).
WARNING: Prior to installing the rocker shafts,
ensure the camshaft sprocket alignment pin on the
camshaft is in the 12 o’clock position. Failure to
position the camshaft may result in damage to the
valvetrain and pistons.
(4) Lubricate the roller portion of the rocker arms
with clean engine oil.
(5) Install
the
rocker
shaft/roller
rocker
arm
assemblies on the camshaft bearing caps, camshaft,
and valve stems.
(6) Hand start rocker shaft/camshaft bearing cap
bolts.
NOTE: When tightening the rocker shaft/camshaft
bearing cap bolts, ensure the camshaft bearing
caps are fully seated and the roller rocker arms
remain seated in their proper position.
Fig. 43 Rocker Arm Shafts/Lash Adjusters/Camshaft
1 - EXHAUST VALVE ROCKER ARM
2 - INTAKE VALVE ROCKER ARM SPACER
3 - INTAKE VALVE ROCKER SHAFT
4 - INTAKE VALVE ROCKER ARM
5 - CAMSHAFT
6 - CAMSHAFT BEARING CAP
7 - EXHAUST VALVE ROCKER SHAFT
Fig. 44 Checking Camshaft for Wear
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
9 - 38
ENGINE 1.6L SOHC
PT
CAMSHAFT (Continued)
(7) Tighten the rocker shaft/camshaft bearing cap
bolts gradually in the sequence shown in (Fig. 45).
Final torque all bolts to 25 N·m (225 in. lbs.).
NOTE: It may be necessary to use the flats on the
front of the camshaft to slightly rotate camshaft for
camshaft sprocket installation.
(8) Slide camshaft sprocket off Special Tool 8446
and into it’s mounting position. Remove Special Tool
8446 from cylinder head (Fig. 42).
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.
(9) Install camshaft sprocket bolt. While holding
the camshaft sprocket with Special Tool 8435, torque
bolt to 115 N·m (85 ft. lbs.) (Fig. 41).
(10) Install camshaft position sensor. Torque fas-
tener to 10 N·m (85 in. lbs.). Reconnect connector.
(11) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER - INSTALLATION).
(12) Connect negative battery cable.
VALVE SPRINGS AND SEALS
(ON VEHICLE SERVICE)
STANDARD PROCEDURE - VALVE SPRINGS
AND SEALS (ON VEHICLE SERVICE)
(1) Disconnect negative battery cable.
(2) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(3) Remove intake and exhaust rocker shaft/rocker
arm assemblies (Refer to 9 - ENGINE/CYLINDER
HEAD/ROCKER
ARM
/
ADJUSTER
ASSY
-
REMOVAL).
(4) Install Special Tool 8813 Adapter Studs/Spacers
as shown in (Fig. 46).
(5) Install Special Tool MD998772A Compressor
with Special Tool 6779 adapter as shown in (Fig. 46).
CAUTION: When removing spark plugs, use Special
Tool 8448 Protective Sleeve on extension (Fig. 47)
or damage to spark plug tubes may result.
(6) Remove spark plugs.
(7) Rotate crankshaft until piston of cylinder being
worked on is at TDC.
(8) Install air hose attached to adapter tool in
spark plug hole. Apply 90-120 psi of air pressure to
the cylinder (Fig. 46).
(9) Using Special Tool MD998772A with adapter
6779 (Fig. 46), compress valve spring and remove
valve locks.
(10) Release tension on valve spring. Remove valve
spring retainer and valve spring.
(11) Remove valve seal/spring seat (Fig. 48).
(12) Replace valve seal/spring seat (Fig. 50).
(13) Install valve spring and valve spring retainer.
(14) Using Special Tool MD998772A with adapter
6779 (Fig. 46), compress valve spring and install
valve locks.
(15) Release tension on valve spring.
(16) Repeat above procedures on remaining cylin-
ders.
(17) Remove
Special
Tools
MD998772A,
6779,
8813.
(18) Install intake and exhaust rocker shaft/rocker
arm assemblies (Refer to 9 - ENGINE/CYLINDER
HEAD/ROCKER ARM / ADJUSTER ASSY - INSTAL-
LATION).
(19) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER - INSTALLATION).
(20) Install spark plugs.
(21) Connect negative battery cable.
Fig. 45 Rocker Arm Shaft Tightening Sequence
PT
ENGINE 1.6L SOHC
9 - 39
CAMSHAFT (Continued)
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