Chrysler PT Cruiser. Manual — part 208
REMOVAL
(1) Disconnect negative battery cable located under
the passenger seat.
(2) Remove engine cover.(Refer to 9 - ENGINE -
REMOVAL).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
RISK OF POISONING FROM INHALING OR SWAL-
LOWING FUEL. RISK OF INJURY FROM SKIN AND
EYE CONTACT WITH FUEL. WEAR PROTECTIVE
CLOTHING. STORE FUEL ONLY IN SUITABLE AND
APPROPRIATELY MARKED CONTAINERS.
(3) Remove
high
pressure
lines
and
injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(4) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(5) Position piston of cylinder #1 to ignition TDC
(Fig. 20).
(6) Install special tool #8929, camshaft locking pin
(Fig. 21).
(7) Remove starter and position out of the way.
(8) Install special tool #8933 crankshaft lock.
(9) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - REMOVAL).
NOTE: The lower portain of the cylinder head front
cover is sealed with RTV sealant. Carefully tug front
cover after bolt removal to loosen from cylinder
head.
(10) Remove cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(11) Remove top side rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
CAUTION: For all work in which the crankshaft
should not rotate, secure camshaft gear to timing
chain.
(12) Mark camshaft sprocket relative to timing
chain.
(13) Unbolt camshaft sprocket from exhaust cam-
shaft.
NOTE: Note the position of dowel pin for camshaft
sprocket alignment during reassembly.
(14) Remove camshaft sprocket.
CAUTION: Camshaft bearing caps must remain in
proper order and position.
(15) Mark and remove camshaft bearing caps.
(16) Remove the inlet and exhaust camshafts (Fig.
22).
INSTALLATION
CAUTION: The camshafts are sensitive to fractur-
ing. Ensure they are installed free of stress.
CAUTION: Pay attention to assignment of cam-
shafts. Camshaft code numbers are visible on the
thrust collar of the axial bearing.
Fig. 20 Camshaft Alignment - Typical
1 - EXHAUST CAMSHAFT SPROCKET AND CHAIN MARKING
2 - EXHAUST CAMSHAFT SPROCKET BOLTS
3 - EXHAUST CAMSHAFT SPROCKET
4 - CAMSHAFT ALIGNMENT DOTS
5 - INTAKE CAMSHAFT LOCK POSITION
6 - INTAKE CAMSHAFT SPROCKET
7 - SPECIAL TOOL 8929
8 - INTAKE CAMSHAFT SPROCKET
9 - 28
ENGINE
PT
CAMSHAFT(S) (Continued)
CAUTION: Oil bucket tappets and camshaft bearing
points. Inspect ease of operation of bucket tappets.
(1) Install inlet and exhaust camshafts.
CAUTION: Install camshafts so that the two holes in
camshaft sprockets are positioned opposite and the
markings of the camshaft and camshaft bearing cap
are aligned.
(2) Align inlet and exhaust camshafts at axial
bearing (Refer to 9 - ENGINE/CYLINDER HEAD/
CAMSHAFT(S) - STANDARD PROCEDURE).
(3) Position piston of cylinder #1 to 30° TDC.
NOTE: Pay attention to markings on camshaft bear-
ing caps.
(4) Install camshaft bearing caps in the proper
order. Tighten bolts to 9N·m (80 lbs. in.).
CAUTION: Do not rotate engine counter clockwise.
(5) Position the piston of cylinder #1 to ignition
TDC.
NOTE: Pay attention to markings on camshaft bear-
ing caps.
(6) Install the bearing caps in reverse order at the
same point. Tighten bearing cap bolts evenly in steps
each of 1 turn.
NOTE: The piston of cylinder #1 must be positioned
at ignition TDC when the inlet camshaft is locked.
(7) Insert locking pin through the first camshaft
bearing cap into the whole in the camshaft sprocket.
NOTE: Do Not use old camshaft sprocket bolts.
(8) Fit camshaft sprocket with timing chain fitted
on, onto exhaust camshaft paying attention to posi-
tion of dowel pin. Tighten bolt to 18N·m (159 lbs.in.).
(9) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(10) Inspect/Set basic position of camshafts (Refer
to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) -
STANDARD PROCEDURE).
(11) Remove special tool #8933, crankshaft lock.
(12) Install starter.
(13) Remove special tool #8929, camshaft locking
pin.
Fig. 21 Special Tool 8929-Camshaft Locking Pin
1 - SPECIAL TOOL 8929
2 - INTAKE CAMSHAFT SPROCKET
3 - ITERMEDIATE GEAR COVER
Fig. 22 Camshafts and Housing Assembly - Typical
1 - CYLINDER HEAD BOLTS
2 - EXHAUST CAMSHAFT
3 - INTAKE CAMSHAFT
4 - CAMSHAFT HOUSING
5 - CYLINDER HEAD
PT
ENGINE
9 - 29
CAMSHAFT(S) (Continued)
(14) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION).
NOTE: Refer to the appropriate injector servicing
procedures for cleaning of injectors and recesses.
(15) Clean and install injectors (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE), (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).
(16) Reconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(17) Start engine and inspect for leaks.
(18) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
ENGINE BLOCK
STANDARD PROCEDURE
REPLACING ENGINE CORE AND OIL GALLERY
PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 23).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopar
t
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
MEASURING CYLINDER BORES
NOTE: This must be done with engine completely
disassembled.
(1) Thoroughly clean all cylinder bores with appro-
priate cleaning solvent.
(2) Measure each cylinder at the three measuring
points shown (Fig. 24).
(3) Using the three measurment point, measure
cylinder in the longitudinal and in the transverse
direction (Fig. 24).
(4) Use the measurment and table below to group
cylinder bores:
Standard size
88.0 mm
Group code letter A
88.000-88.006 mm
Group code letter X
88.006-88.012 mm
Group code letter B
88.012-88.018 mm
Wear limit in longitudinal
in transverse direction
0.020 mm
Permissible variation of
cylinder shape (when
new)
0.000-0.014 mm
Fig. 23 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 30
ENGINE
PT
CAMSHAFT(S) (Continued)
CRANKSHAFT
STANDARD PROCEDURE
MEASURE CRANKSHAFT AND BLOCK
JOURNALS
NOTE: After any bearing damage occurred, remove
all debris which is present in the main oil gallery,
connecting rod bores, and in the crankshaft and oil
galleries. Include removal of the inserting steel ball
of the main oil gallery before cleaning.
(1) Remove crankshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT - REMOVAL).
(2) Clean all engine parts thoroughly.
CAUTION: After bearing has damage has occurred,
replace connecting rods which have suffered over-
heating because of bearing damage. The connect-
ing rod must not have any cross scores and
notches.
(3) Inspect connecting rod. If damage is present,
inspect crankshaft, replace as necessary.
(4) Inspect crankcase.
(5) Inspect standard size of crankshaft bearing
shells.
(6) Inspect crankshaft bearing cap.
(7) Mount crankshaft radially.
(8) Inspect crankshaft bearing play.
NOTE: Radial mounting of the main bearings of
standard size crankshaft is possible by assigning
the color-coded bearing shells.
ASSIGN CRANKSHAFT BEARING SHELLS
The oil pan rail of the cylinder block is marked
with chisel punches indicating what bearing shell are
used.
(9) Assign crankshaft bearing shells.
(10) Mount crankshaft axially.
(11) Inspect crankshaft bearing play.
REMOVAL
NOTE: The engine must be removed from the vehi-
cle to service crankshaft.
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Remove engine (Refer to 9 - ENGINE -
REMOVAL).
Fig. 24 Measuring Cylinder Bores
1 - MEASURING POINT OF CYLINDER BORE
2 - MEASURING POINT OF CYLINDER BORE
3 - MEASURING POINT OF CYLINDER BORE
1a - UPPER REVERSAL POINT OF #1 PISTON RING
1b - BOTTOM DEAD CENTER OF PISTON
1c - BOTTOM REVERSAL POINT OF OIL SCRAPER RING
1A - LONGITUDINAL DIRECTION
1B - TRANSVERSE DIRECTION
PT
ENGINE
9 - 31
ENGINE BLOCK (Continued)
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