Chrysler PT Cruiser. Manual — part 688
(17) Install camshaft position sensor. Torque fas-
tener to 10 N·m (85 in. lbs.). Reconnect connector.
(18) Install right engine mount bracket (Refer to 9
- ENGINE/ENGINE MOUNTING/ENGINE MOUNT
BRACKET - INSTALLATION).
(19) Lower
engine
until
right
engine
mount
through bolt can be installed.
(20) Install right engine mount through bolt.
(21) Remove floor jack from under engine.
(22) Install
fastener
securing
power
steering
return line to right engine mount bracket.
(23) Install fasteners securing power steering res-
ervoir to right engine mount bracket.
(24) Install upper torque strut.
(25) Raise vehicle on hoist.
(26) Install fasteners securing exhaust pipe to exhaust
manifold. Torque fasteners to 28 N·m (250 in. lbs.).
(27) Install lower torque strut.
(28) Install accessory drive belt splash shield.
(29) Install right front wheel.
(30) Lower vehicle.
(31) Connect upper radiator hose.
(32) Install fastener securing heater return tube to
thermostat housing.
(33) Connect heater hoses to thermostat housing
and heater return tube.
(34) Connect the following electrical components:
• Upstream Oxygen Sensor
• Camshaft Position Sensor
• Ignition Coil and Capacitor
• Fuel Injectors
• MAP Sensor
• Knock Sensor
• Electronic Throttle Control Motor
• ECT Sensor
• Generator
(35) Connect vacuum hoses to throttle body.
(36) Connect ground strap to cylinder head.
(37) Connect throttle body air inlet hose.
(38) Connect negative battery cable.
(39) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(40) Perform torque strut adjustment procedure
(Refer
to
9
-
ENGINE/ENGINE
MOUNTING/
TORQUE STRUT - ADJUSTMENTS).
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL).
(3) Disconnect make-up air hose and PCV hoses
(Fig. 28) from cylinder head cover.
(4) Disconnect the ignition coil and capacitor elec-
trical connectors.
(5) Remove the spark plug cables, twist spark plug
boots, then pull straight up.
(6) Remove ignition coil bolts and then remove the
ignition coil and spark plug cables as an assembly.
(7) Remove ignition coil capacitor.
(8) Remove cylinder head cover bolts.
(9) Remove cylinder head cover (Fig. 29).
Fig. 28 PCV Valve Location
Fig. 29 Cylinder Head Cover
9 - 32
ENGINE 1.6L SOHC
PT
CYLINDER HEAD (Continued)
CLEANING
Clean cylinder head and cover mating surfaces
using a suitable solvent.
INSPECTION
Inspect cover rails for flatness.
INSTALLATION
(1) Inspect gasket and seals (Fig. 30). Replace as
necessary. For replacement of spark plug tube seals,
(Refer to 9 - ENGINE/CYLINDER HEAD/SPARK
PLUG TUBE SEAL - REMOVAL) and (Refer to 9 -
ENGINE/CYLINDER HEAD/SPARK PLUG TUBE
SEAL - INSTALLATION).
(2) Install cylinder head cover and gasket. The cyl-
inder head cover bolts have to be tightened in 2 steps
and in a tightening sequence. The first torque is to
tighten the bolts to 6 N·m (60 in. lbs.) then tighten
the bolts to 12 N·m (105 in. lbs.) (Fig. 31).
(3) Install ignition coil capacitor.
(4) Install ignition coil and spark plug cables.
Make sure the rubber insulators are in place on the
ignition coil (Fig. 32). Tighten ignition coil fasteners
to 12 N·m (105 in. lbs.).
(5) Connect make-up air and PCV hoses (Fig. 28).
(6) Connect the ignition coil and capacitor electri-
cal connectors.
(7) Install upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
INSTALLATION).
(8) Connect the negative battery cable.
Fig. 30 Cylinder Head Cover Gasket and Seals
1 - CYLINDER HEAD COVER GASKET
2 - SEAL
3 - BOLT
4 - SPARK PLUG TUBE SEALS
Fig. 31 Cylinder Head Cover Tightening Sequence
Fig. 32 Rubber Insulators and Ignition Coil
1 - Rubber Insulators
2 - Coil
PT
ENGINE 1.6L SOHC
9 - 33
CYLINDER HEAD COVER (Continued)
SPARK PLUG TUBE SEAL
DESCRIPTION
The spark plug tube seals are located in the cylin-
der head cover (Fig. 33). These seals are pressed into
the cylinder head cover to seal the outside perimeter
of the spark plug tubes. If these seals show signs of
hardness and/or cracking, they should be replaced.
REMOVAL
(1) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER - REMOVAL).
(2) Using an appropriate tool, carefully remove
spark plug tube seals (Fig. 33). Care should be taken
not to damage cylinder head cover sealing surfaces.
INSTALLATION
(1) Clean all sealing surfaces.
NOTE: Position seal with the concave side facing
the installation tool (Fig. 34).
(2) Install seals using Special Tool MB-998306
(Fig. 34). Only hand pressure on tool is needed to
install new seals.
(3) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER - INSTALLATION).
SPARK PLUG TUBE
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL).
(3) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(4) Remove lower intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL).
(5) Position Special Tool 8819 on spark plug tube.
Tighten the set screws to 16 N·m (142 in. lbs.) (Fig.
35).
(6) Using the Special Tool C-3752 attached to
8819, remove the tube from the cylinder head (Fig.
35).
(7) Loosen the set screws and rotate Special Tool
8819 one-quarter turn to remove from the tube. Dis-
card the tube.
INSTALLATION
(1) Clean area around spark plug with Mopar
t
parts cleaner or equivalent.
(2) Apply Mopar
t Stud and Bearing Mount or
equivalent to a new tube approximately 1 mm (0.039
in.) from the end in a 3 mm (0.118 in.) wide area.
(3) Remove the spark plug.
(4) Install Special Tool 8447–1 into the spark plug
bore (Fig. 36).
(5) Install sealer end of tube into the cylinder
head. Carefully install the tube using Special Tool
Fig. 33 Spark Plug Tube Seals
1 - SPARK PLUG TUBE SEAL
2 - CYLINDER HEAD COVER
Fig. 34 Spark Plug Tube Seal Installation
1 - SPECIAL TOOL MD-998306
2 - SPARK PLUG TUBE SEAL
9 - 34
ENGINE 1.6L SOHC
PT
8447–2 Installer and mallet until Special Tool 8447–2
bottoms against 8447–1 (Fig. 37).
(6) Unscrew Special Tool 8447–1 from the spark
plug bore. Using the long bolt (8447–3), remove Spe-
cial Tool 8447–1 (Fig. 38).
(7) Install the spark plug.
(8) Install lower intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
INSTALLATION).
Fig. 35 Spark Plug Tube - Removal
1 - SPECIAL TOOL C-3752
2 - SPECIAL TOOL 8819
3 - SET SCREWS
Fig. 36 Special Tool 8447-1
1 - SPECIAL TOOL 8447-1
Fig. 37 Spark Plug Tube Installation
1 - SPECIAL TOOL 8447-2
Fig. 38 8447-1 Removal
1 - SPECIAL TOOL 8447-3 (BOLT)
2 - SPARK PLUG TUBE
PT
ENGINE 1.6L SOHC
9 - 35
SPARK PLUG TUBE (Continued)
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