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INSPECTION Chrysler PT Cruiser I

1.6l SOHC Engine 19 illustrations ~2046 words

INSPECTION

Inspect cover rails for flatness.

Scheme 63

Scheme 63: INSTALLATION
Scheme 63: INSTALLATION

Scheme 64

Scheme 64
Scheme 64

Scheme 65

Scheme 65
Scheme 65
  1. Inspect gasket and seals. (Scheme 63) Replace as necessary. For replacement of spark plug tube seals, «(Refer to ENGINE/CYLINDER HEAD/SPARK PLUG TUBE SEAL - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) and «(Refer to ENGINE/CYLINDER HEAD/SPARK PLUG TUBE SEAL - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine). 1 - CYLINDER HEAD COVER GASKET 2 - SEAL 3 - BOLT 4 - SPARK PLUG TUBE SEALS
  2. Install cylinder head cover and gasket. The cylinder 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.). (Scheme 64)
  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. (Scheme 65) Tighten ignition coil fasteners to 12 N.m (105 in. lbs.). 1 - Rubber Insulators 2 - Coil
  5. Connect make-up air and PCV hoses. (Scheme 61)
  6. Connect the ignition coil and capacitor electrical connectors.
  7. Install upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  8. Connect the negative battery cable.

The spark plug tube seals are located in the cylinder head cover. (Scheme 66) 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.

  1. Remove the cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  2. Using an appropriate tool, carefully remove spark plug tube seals. (Scheme 66) Care should be taken not to damage cylinder head cover sealing surfaces.

Scheme 66

Scheme 66
Scheme 66
1 - SPARK PLUG TUBE SEAL
2 - CYLINDER HEAD COVER

Scheme 67

Scheme 67: INSTALLATION
Scheme 67: INSTALLATION
  1. Clean all sealing surfaces. NOTE: Position seal with the concave side facing the installation tool. (Scheme 67)
  2. Install seals using Special Tool MB-998306. (Scheme 67) Only hand pressure on tool is needed to install new seals. 1 - SPECIAL TOOL MD-998306 2 - SPARK PLUG TUBE SEAL
  3. Install the cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).

Scheme 68

Scheme 68: REMOVAL
Scheme 68: REMOVAL
  1. Disconnect negative battery cable.
  2. Remove upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  3. Remove the cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) ).
  4. Remove lower intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  5. Position Special Tool 8819 on spark plug tube. Tighten the set screws to 16 N.m (142 in. lbs.). (Scheme 68)
  6. Using the Special Tool C-3752 attached to 8819, remove the tube from the cylinder head. (Scheme 68) 1 - SPECIAL TOOL C-3752 2 - SPECIAL TOOL 8819 3 - SET SCREWS
  7. Loosen the set screws and rotate Special Tool 8819 one-quarter turn to remove from the tube. Discard the tube.

Scheme 69

Scheme 69: INSTALLATION
Scheme 69: INSTALLATION

Scheme 70

Scheme 70
Scheme 70

Scheme 71

Scheme 71
Scheme 71
  1. Clean area around spark plug with Mopar® parts cleaner or equivalent.
  2. Apply Mopar® 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. (Scheme 69) 1 - SPECIAL TOOL 8447-1
  5. Install sealer end of tube into the cylinder head. Carefully install the tube using Special Tool 8447-2 Installer and mallet until Special Tool 8447-2 bottoms against 8447-1. (Scheme 70) 1 - SPECIAL TOOL 8447-2
  6. Unscrew Special Tool 8447-1 from the spark plug bore. Using the long bolt (8447-3), remove Special Tool 8447-1. (Scheme 71) 1 - SPECIAL TOOL 8447-3 (BOLT) 2 - SPARK PLUG TUBE
  7. Install the spark plug.
  8. Install lower intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  9. Install the cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) ).
  10. Install upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  11. Connect negative battery cable.

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 hydraulic lash adjuster, using oil pressure, constantly maintains 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. (Scheme 72)

  1. Disconnect negative battery cable.
  2. Remove cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine). 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. (Scheme 72)

Note. Hydraulic lash adjusters are replaced as an assembly with the rocker arms.

Scheme 72

Scheme 72
Scheme 72
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

Scheme 73

Scheme 73: INSTALLATION
Scheme 73: 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. (Scheme 72)
  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.
  4. Tighten the rocker shaft/camshaft bearing cap bolts gradually in the sequence (Scheme 73) Final torque all bolts to 25 N.m (225 in. lbs.).
  5. Install cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  6. Connect negative battery cable.

Scheme 74

Scheme 74
Scheme 74
  1. Disconnect negative battery cable.
  2. Remove cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  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. see scheme 74 1 - SPECIAL TOOL 8435
  6. Install Special Tool 8446 (Scheme 74) Hold tool against camshaft and tighten tool mounting bolts.
  7. Slide camshaft sprocket onto Special Tool 8446. (Scheme 74) 1 - SPECIAL TOOL 8446 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.
  9. Remove the rocker shafts/roller rocker arm assemblies. see scheme 76
  10. Remove camshaft bearing caps noting orientation and numbering for reassembly purposes. see scheme 76
  11. Lift camshaft from cylinder head. see scheme 76
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
  1. Inspect camshaft bearing journals for damage and binding. (Scheme 75) 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) and replace camshaft if out of limit. Standard value is 0.0254 mm (0.001 in.), wear (Scheme 75) limit is 0.254 mm (0.010 in.).

Scheme 75

Scheme 75
Scheme 75
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
  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. see scheme 76 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.
  7. Tighten the rocker shaft/camshaft bearing cap bolts gradually in the sequence see scheme 78 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. (Scheme 74) CAUTION: Do Not use an impact wrench for tightening 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.). see scheme 74
  10. Install camshaft position sensor. Torque fastener to 10 N.m (85 in. lbs.). Reconnect connector.
  11. Install cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  12. Connect negative battery cable.

Scheme 76

Scheme 76: STANDARD PROCEDURE - VALVE SPRINGS AND SEALS (ON VEHICLE SERVICE)
Scheme 76: STANDARD PROCEDURE - VALVE SPRINGS AND SEALS (ON VEHICLE SERVICE)

Scheme 77

Scheme 77
Scheme 77

Scheme 78

Scheme 78
Scheme 78
  1. Disconnect negative battery cable.
  2. Remove cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) ).
  3. Remove intake and exhaust rocker shaft/rocker arm assemblies «(Refer to ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  4. Install Special Tool 8813 Adapter Studs/Spacers (Scheme 76)
  5. Install Special Tool MD998772A Compressor with Special Tool 6779 adapter (Scheme 76) 1 - SPECIAL TOOL MD998772A 2 - SPECIAL TOOL 6779 ADAPTER 3 - SPECIAL TOOL 8813 ADAPTER STUDS/SPACERS 4 - AIR HOSE CAUTION: When removing spark plugs, use Special Tool 8448 Protective Sleeve on extension or damage to spark plug tubes may result. (Scheme 77)
  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. (Scheme 76)
  9. Using Special Tool MD998772A with adapter 6779, compress valve spring and remove valve locks. (Scheme 76)
  10. Release tension on valve spring. Remove valve spring retainer and valve spring.
  11. Remove valve seal/spring seat. (Scheme 78) 1 - VALVE SEAL TOOL 2 - VALVE STEM
  12. Replace valve seal/spring seat. (Scheme 80)
  13. Install valve spring and valve spring retainer.
  14. Using Special Tool MD998772A with adapter 6779, compress valve spring and install valve locks. (Scheme 76)
  15. Release tension on valve spring.
  16. Repeat above procedures on remaining cylinders.
  17. Remove Special Tools MD998772A, 6779, 8813.
  18. Install intake and exhaust rocker shaft/rocker arm assemblies «(Refer to ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  19. Install cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
  20. Install spark plugs.
  21. Connect negative battery cable.

Scheme 79

Scheme 79: STANDARD PROCEDURE - VALVE SPRINGS AND SEALS (CYLINDER HEAD REMOVED)
Scheme 79: STANDARD PROCEDURE - VALVE SPRINGS AND SEALS (CYLINDER HEAD REMOVED)
  1. Compress valve spring using Special Tools C-3422-D Spring Compressor with adapter 6526A. (Scheme 79) 1 - SPECIAL TOOL C-3422-D 2 - SPECIAL TOOL 6526A
  2. Remove valve locks. (Scheme 80)
  3. Release valve spring compressor. Remove valve spring retainer and valve spring.
  4. Remove valve seal/spring seat. (Scheme 78)
  5. Replace valve seal/spring seat.
  6. Install valve spring and valve spring retainer.
  7. Compress valve spring using Special Tools C-3422-D Spring Compressor with adapter 6526A. (Scheme 79)
  8. Install valve locks.
  9. Release Spring compressor.
  10. Repeat procedure for remaining valve springs and seals.

Scheme 80

Scheme 80
Scheme 80
1 - VALVE LOCKS
2 - VALVE SPRING RETAINER
3 - VALVE SPRING
4 - VALVE STEM SEAL/SPRING SEAT
5 - CYLINDER HEAD
6 - INTAKE VALVE
7 - EXHAUST VALVE

When valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. (Scheme 81) As an example; the compression length of the spring to be tested is 38.00 mm (1.496 in.). Turn table of Tool C-647 until surface is in line with the 38.00 mm (1.496 inches.) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to Engine Specifications to obtain specified height and allowable tensions (Refer to ENGINE - SPECIFICATIONS). Replace springs that do not meet specifications.

Scheme 81

Scheme 81: INSPECTION
Scheme 81: INSPECTION
1 - SPECIAL TOOL C-647