1.6l SOHC Engine Chrysler PT Cruiser I

DESCRIPTION

The 1.6 Liter (97.6 cu. in.) in-line four cylinder engine is a single over head camshaft with four valves per cylinder design. The engine does not have provisions for a "free wheeling" valve train.

The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2.

The engine identification number is stamped onto a machined pad located on the right front of the cylinder block below the cylinder head sealing surface. (Scheme 1)

Scheme 1

INTRODUCTION

Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance.

These malfunctions may be classified as either mechanical (e.g, a strange noise), or performance (e.g, engine idles rough and stalls).

Refer to the Engine Mechanical and the Engine Performance diagnostic charts, for possible causes and corrections of malfunctions. Refer to ENGINE MECHANICAL and ENGINE PERFORMANCE .

For fuel system diagnosis, (Refer to FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING) .

Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following

1. «CYLINDER COMPRESSION PRESSURE TEST»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine__cylinder-compression-pressure-test)
2. «CYLINDER COMBUSTION PRESSURE LEAKAGE TEST»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine__cylinder-combustion-pressure-leakage-test)
3. «CYLINDER HEAD GASKET»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine__cylinder-head-gasket) Failure Diagnosis
4. «LASH ADJUSTER NOISE DIAGNOSIS»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine__lash-adjuster-noise-diagnosis)
5. «ENGINE OIL LEAK INSPECTION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine__engine-oil-leak-inspection)

ENGINE PERFORMANCE

ENGINE MECHANICAL

CYLINDER COMPRESSION PRESSURE TEST

The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.

Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.

Scheme 2

1. Check engine oil level and add oil if necessary.
2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. CAUTION: When removing spark plugs, use Special Tool 8448 Protective Sleeve on extension or damage to spark plug tubes may result. (Scheme 2)
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference.
4. Remove the Auto Shutdown (ASD) relay from the PDC.
5. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRBIII®. For Special Tool identification, «(Refer to ENGINE - SPECIAL TOOLS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
6. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders.
8. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder.
9. If one or more cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present.

CYLINDER COMBUSTION PRESSURE LEAKAGE TEST

The combustion pressure leakage test provides an accurate means for determining engine condition.

Combustion pressure leakage testing will detect

1. Exhaust and intake valve leaks (improper seating).
2. Leaks between adjacent cylinders or into water jacket.
3. Any causes for combustion/compression pressure loss.

Check the coolant level and fill as required. DO NOT install the pressure cap.

Start and operate the engine until it attains normal operating temperature, then turn the engine OFF.

Clean spark plug recesses with compressed air.

Remove the spark plugs.

Remove the oil filler cap.

Remove the air cleaner.

Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379 kPa (200 psi) maximum, with 552 kPa (80 psi) recommended.

Perform the test procedures on each cylinder according to the tester manufacturer's instructions. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler cap opening. Check for bubbles in the coolant.

All gauge pressure indications should be equal, with no more than 25% leakage per cylinder.

FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained in the cylinder.

CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket.

Possible indications of the cylinder head gasket leaking between adjacent cylinders are

1. Loss of engine power
2. Engine misfiring
3. Poor fuel economy

Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are

1. Engine overheating
2. Loss of coolant
3. Excessive steam (white smoke) emitting from exhaust
4. Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the procedures in Cylinder Compression Pressure Test (Refer to ENGINE - DIAGNOSIS AND TESTING) . An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50-70% reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

VISUAL TEST METHOD

With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens.

If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.

COOLING SYSTEM TESTER METHOD

Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester's pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.

CHEMICAL TEST METHOD

Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit.

LASH ADJUSTER NOISE DIAGNOSIS

A tappet-like noise may be produced from several items. Check the following items.

1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy.
2. Insufficient running time after rebuilding cylinder head. Low speed running up to 1 hour may be required.
3. During this time, turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature.
4. Low oil pressure.
5. The oil restrictor (integral to the head gasket) in the vertical oil passage to the cylinder head is plugged with debris.
6. Air ingested into oil due to broken or cracked oil pump pick up.
7. Worn valve guides.
8. Rocker arm ears contacting valve spring retainer.
9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system.
10. Faulty lash adjuster. Check lash adjusters for sponginess while installed in cylinder head. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. Remove suspected rocker arm/lash adjuster assembly, and replace as necessary.

ENGINE OIL LEAK INSPECTION

Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed

1. Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
2. Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair as necessary.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles), and repeat inspection.
5. If the oil leak source is not positively identified at this time , proceed with the air leak detection test method as follows: Disconnect the fresh air hose (make-up air) at the cylinder head cover and plug or cap the nipple on the cover. Remove the PCV valve hose from the cylinder head cover. Cap or plug the PCV valve nipple on the cover. Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kpa (3 PSI) of test pressure. Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provides the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service information procedures. If the leakage occurs at the crankshaft rear oil seal area, refer to «INSPECTION FOR REAR SEAL AREA LEAKS»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine__inspection-for-rear-seal-area-leaks) .
6. If no leaks are detected, turn off the air supply. Remove the air hose, all plugs, and caps. Install the PCV valve and fresh air hose (make-up air). Proceed to next step.
7. Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.

Note. If oil leakage is observed at the dipstick tube to block location; remove the tube, clean and reseal using Mopar® Stud & Bearing Mount (press fit tube applications only), and for O-ring style tubes, remove tube and replace the O-ring seal.

INSPECTION FOR REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.

If the leakage occurs at the crankshaft rear oil seal area

1. Disconnect the battery.
2. Raise the vehicle.
3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak. If a leak is present in this area, remove transmission for further inspection. Circular spray pattern generally indicates seal leakage or crankshaft damage. Where leakage tends to run straight down, possible causes are a porous block, oil gallery cup plug, bedplate to cylinder block mating surfaces and seal bore. See proper repair procedures for these items.
4. If no leaks are detected, pressurize the crankcase as previously described. CAUTION: Do not exceed 20.6 kPa (3 psi).
5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal.
6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled.
7. After the oil leak root cause and appropriate corrective action have been identified, replace component(s) as necessary.

REPAIR OF DAMAGED OR WORN THREADS

Damaged or worn threads (excluding spark plug and camshaft bearing cap attaching threads) can be repaired. Essentially, this repair consists of drilling out worn or damaged threads, tapping the hole with a special Heli-Coil Tap, (or equivalent) and installing an insert into the tapped hole. This brings the hole back to its original thread size.

Heli-Coil tools and inserts are readily available from automotive parts jobbers.

HYDROSTATIC LOCKED ENGINE

When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used.

1. Inspect air cleaner, induction system and intake manifold to insure system is dry and clear of foreign material.
2. Remove negative battery cable.
3. Place a shop towel around the spark plugs when removing them from the engine. This will catch any fluid that may possibly be in the cylinder under pressure.
4. With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket.
5. Identify the fluid in the cylinder(s) (i.e, coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e, connecting rods, pistons, valves, etc.)
7. Repair engine or components as necessary to prevent this problem from re-occurring. CAUTION: Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart.
8. Install new spark plugs.
9. Drain engine oil and remove oil filter.
10. Install a new oil filter.
11. Fill engine with specified amount of approved oil.
12. Connect negative battery cable.
13. Start engine and check for any leaks.

FORM-IN-PLACE GASKETS AND SEALERS

There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.

There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other.

MOPAR® ENGINE RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.

MOPAR® GASKET MAKER is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.

MOPAR® BED PLATE SEALANT is a unique (green-in-color) anaerobic type gasket material that is specially made to seal the area between the bed plate and cylinder block without disturbing the bearing clearance or alignment of these components. The material cures slowly in the absence of air when torqued between two metallic surfaces, and will rapidly cure when heat is applied.

MOPAR® GASKET SEALANT is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.

SEALER APPLICATION

Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.

ENGINE GASKET SURFACE PREPARATION

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Never use the following to clean gasket surfaces

1. Metal scraper
2. Abrasive pad or paper to clean cylinder block and head
3. High speed power tool with an abrasive pad or a wire brush. (Scheme 3)

Note. Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces

1. Solvent or a commercially available gasket remover
2. Plastic or wood scraper. (Scheme 3)
3. Drill motor with 3M Roloc™ Bristle Disc (white or yellow). (Scheme 3)

Scheme 3

MEASURING BEARING CLEARANCE USING PLASTIGAGE

Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage

Scheme 4

1. Remove oil film from surface to be checked. Plastigage is soluble in oil.
2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 in.) off center and away from the oil holes. (Scheme 4) (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap/bed plate bolts of the bearing being checked to the proper specifications. 1 - PLASTIGAGE
3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Compare clearance measurements to specs found in engine specifications «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine). Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking.
4. Install the proper crankshaft bearings to achieve the specified bearing clearances.

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 suitable tool and remove plug. (Scheme 5)

Scheme 5

Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopar® 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.

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. Perform fuel pressure release procedure «(Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/fuel-system/#fuel-system).
2. Remove throttle body air inlet hose and air cleaner housing assembly.
3. Disconnect negative battery cable.
4. Disconnect positive battery cable. Remove battery and battery tray. (Scheme 6)and (Scheme 7). 1 - BATTERY 1 - BATTERY TRAY
5. Drain cooling system «(Refer to COOLING/ENGINE - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
6. Discharge air conditioning system, if equipped (Refer to «HEATING & AIR CONDITIONING»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information) ).
7. Disconnect engine wiring harness at Powertrain Control Module (PCM).
8. Disconnect positive cable from Power Distribution Center (PDC) and ground wire from vehicle body. Remove bolts attaching PDC and set aside. (Scheme 8) 1 - PDC 2 - PDC BRACKET BOLTS 3 - BATTERY TRAY BOLT
9. Disconnect coolant recovery container hose from radiator neck.
10. Disconnect heater hoses at thermostat housing and heater return tube.
11. Disconnect wiring connectors at lower battery tray support.
12. Remove upper radiator support crossmember «(Refer to BODY/EXTERIOR/RADIATOR CROSSMEMBER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
13. Remove upper radiator hose.
14. Remove lower radiator hose.
15. Disconnect upper A/C line from A/C condenser.
16. Disconnect A/C lines at junction near upper torque strut.
17. Disconnect radiator fan electrical connector and remove cooling module assembly (fan, radiator, A/C condenser).
18. Disconnect transmission shift cables and transmission electrical connectors.
19. Disconnect brake booster and purge solenoid vacuum hoses.
20. Disconnect ground strap at cylinder head.
21. Remove fasteners holding power steering return line to right engine bracket. Remove fasteners holding power steering reservoir to right engine bracket. Disconnect reservoir hose from power steering pump. Reposition reservoir out of way.
22. Raise vehicle on hoist.
23. Drain engine oil.
24. Remove both front wheels.
25. Remove accessory drive belt splash shield.
26. Remove accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system__removal).
27. Remove pencil strut and lower torque strut. (Scheme 9) 1 - PENCIL STRUT 2 - TORQUE STRUT FASTENERS 3 - LOWER TORQUE STRUT
28. Remove left and right drive axles «(Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/axle-shafts/#differential-driveline__removal).
29. Remove fasteners securing exhaust pipe to exhaust manifold.
30. Remove clutch slave cylinder and damper fasteners. (Scheme 10) Reposition and support with suitable strap. 1 - DAMPER FASTENERS 2 - CLUTCH SLAVE CYLINDER FASTENERS
31. Disconnect power steering pressure line from power steering pump.
32. Disconnect A/C compressor electrical connectors.
33. Remove A/C compressor mounting bolts. Remove A/C compressor.
34. Lower vehicle.
35. Disconnect fuel line from fuel rail.
36. Raise vehicle enough to allow engine dolly, cradle, and posts, (Special Tools 6135, 6710, and 6848) to be installed under vehicle. For Special Tool identification «(Refer to ENGINE - SPECIAL TOOLS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
37. Loosen engine support posts to allow movement for positioning onto engine locating holes. (Scheme 13) Position wooden blocks under oil pan. (Scheme 13) Lower vehicle and position cradle until the engine is resting on support posts and wooden blocks. (Scheme 13) Tighten post mounts to cradle frame. This will keep support posts from moving when removing or installing engine and transmission.
38. Install safety straps around the engine to cradle. (Scheme 13) Tighten straps and lock them into position. WARNING: Safety straps MUST be used to secure engine to the dolly fixture.
39. Raise vehicle enough to see if straps are tight enough to hold cradle assembly to engine.
40. Lower vehicle so weight of the engine and transmission ONLY is on the cradle assembly.
41. Remove upper torque strut. (Scheme 11) 1 - BOLTS 2 - RIGHT FENDER 3 - UPPER TORQUE STRUT BRACKET 4 - NUTS 5 - BOLT 6 - UPPER TORQUE STRUT 7 - ENGINE MOUNT BRACKET 8 - BOLT 9 - LOWER TORQUE STRUT 10 - BOLT 11 - RIGHT ENGINE MOUNT
42. Remove right mount through bolt and left mount attaching bolts. (Scheme 11)and (Scheme 12). 1 - BOLT 2 - TRANSAXLE 3 - LEFT MOUNT
43. Continue raising vehicle slowly until engine/transaxle assembly clears engine compartment. It may be necessary to move the engine/transmission assembly with the cradle to allow for removal around body flanges.

Scheme 13

INSTALLATION - ENGINE ASSEMBLY

1. Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine/transaxle assembly.
2. Continue lowering vehicle until engine/transaxle aligns to mounting locations. Install mounting bolts at the right and left engine/transaxle mounts. (Scheme 11)and (Scheme 12). Tighten bolts to 118 N.m (87 ft. lbs.).
3. Install the upper engine torque strut. (Scheme 11)
4. Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly and cradle.
5. Raise vehicle.
6. Install A/C compressor mounting bolts. Reconnect A/C compressor electrical connectors.
7. Connect power steering pressure line to power steering pump.
8. Install fasteners securing clutch slave cylinder and damper. (Scheme 10)
9. Connect exhaust pipe to exhaust manifold. Install fasteners and torque to 28 N.m (250 in. lbs.).
10. Install left and right drive axles «(Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/axle-shafts/#differential-driveline__installation).
11. Install pencil strut and lower torque strut. (Scheme 9)
12. Install accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system__installation).
13. Install accessory drive belt splash shield.
14. Install both front wheels.
15. Lower vehicle.
16. Connect fuel line to fuel rail.
17. Connect power steering reservoir hose to power steering pump. Install fastener securing power steering return line to right engine bracket. Install fasteners securing power steering reservoir bracket to right engine bracket.
18. Connect ground strap to cylinder head.
19. Connect brake booster and purge solenoid vacuum hoses.
20. Connect transmission shift cables and transmission electrical connectors.
21. Install cooling module assembly (fan, radiator, A/C condenser). Connect radiator fan electrical connector.
22. Connect A/C lines at junction near upper torque strut.
23. Connect upper A/C line to A/C condenser.
24. Connect upper and lower radiator hoses.
25. Install upper radiator crossmember «(Refer to BODY/EXTERIOR/RADIATOR CROSSMEMBER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
26. Connect heater hoses to thermostat housing and heater return tube.
27. Connect coolant recovery container hose to radiator neck.
28. Install bolts attaching Power Distribution Center (PDC). Connect positive cable to PDC and ground wire to vehicle body. (Scheme 8)
29. Connect engine wiring harness at Powertrain Control Module (PCM).
30. Install battery tray and battery. (Scheme 6)and (Scheme 7). Connect positive battery cable.
31. Connect negative battery cable.
32. Install air cleaner housing and throttle body air inlet hose.
33. Install new oil filter. Fill engine crankcase with proper oil to correct level.
34. Fill power steering system.
35. Fill Cooling system «(Refer to COOLING/ENGINE - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
36. Evacuate and recharge A/C system (Refer to «HEATING & AIR CONDITIONING»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information) ).
37. Start engine and run until operating temperature is reached.
38. Perform torque strut adjustment procedure «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
39. Adjust transmission linkage, if necessary.

GENERAL SPECIFICATIONS

ENGINE BLOCK

PISTONS

PISTON PINS

PISTON RINGS

CONNECTING ROD

CRANKSHAFT

ROCKER ARM SHAFT

ROCKER ARM/HYDRAULIC LASH ADJUSTER

CYLINDER HEAD CAMSHAFT BEARING BORE

CAMSHAFT

CYLINDER HEAD

VALVE SEAT

VALVE GUIDE

VALVES

VALVE MARGIN

VALVE LENGTH

VALVE STEM TIP HEIGHT

VALVE STEM DIAMETER

VALVE STEM TO GUIDE CLEARANCE

VALVE SPRINGS

OIL PUMP

OIL PRESSURE

TORQUE

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

REMOVAL

1. Unsnap the 2 clips holding the air cleaner housing cover.
2. Lift the air cleaner housing cover up.
3. Remove the air cleaner element. (Scheme 47)

Scheme 47

INSTALLATION

1. Install air cleaner element into the air cleaner housing. (Scheme 47)
2. Reposition the air cleaner housing cover.
3. Latch the 2 spring clips.

1. Disconnect the inlet air temperature sensor.
2. Remove the inlet tube to throttle body.
3. Unsnap the 2 clips holding the air cleaner housing cover.
4. Lift the air cleaner housing cover up.
5. Remove the air cleaner element. (Scheme 47)
6. Pull air cleaner housing straight up and off of the 2 locating pins. (Scheme 48)

Scheme 48

1. Install air cleaner housing onto the locating pins.
2. Install the air cleaner element.
3. Install the inlet tube onto the throttle body.
4. Install cover to the air cleaner housing.
5. Latch the 2 spring clips.
6. Connect the electrical connector to the inlet air temperature sensor.

Scheme 49

Scheme 50

Scheme 51

Scheme 52

1. Perform fuel system pressure release procedure «(Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/fuel-system/#fuel-system).
2. Disconnect negative battery cable.
3. Drain cooling system «(Refer to COOLING/ENGINE - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
4. Disconnect throttle body air inlet hose.
5. Disconnect ground strap from cylinder head.
6. Disconnect vacuum hoses from throttle body.
7. Disconnect 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
8. Disconnect heater hoses from thermostat housing and heater return tube.
9. Remove fastener securing heater return tube to thermostat housing.
10. Disconnect upper radiator hose.
11. Raise vehicle on hoist.
12. Remove right front wheel.
13. Remove accessory drive belt splash shield.
14. Remove lower torque strut.
15. Remove lower bolt for right engine mount bracket.
16. Remove fasteners securing exhaust pipe to exhaust manifold.
17. Lower vehicle.
18. Remove upper torque strut.
19. Remove fastener securing power steering return line to right engine mount bracket.
20. Remove fasteners securing power steering reservoir to right engine mount bracket.
21. Support engine with floor jack and wooden block on oil pan.
22. Remove right engine mount through bolt.
23. Jack up engine. Remove remaining fasteners holding right engine mount bracket. Remove right engine mount bracket.
24. Remove camshaft position sensor.
25. 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) ).
26. Rotate crankshaft until triangular timing mark on camshaft sprocket is at the 12 o'clock position.
27. For reassembly purposes, paint the timing chain link that lines up with camshaft timing mark. (Scheme 49) 1 - PAINT THE LINK THAT ALIGNS WITH TIMING MARK 2 - CAMSHAFT SPROCKET TIMING MARK
28. Using Special Tool 8435 to hold camshaft sprocket, remove camshaft sprocket bolt. (Scheme 50) 1 - SPECIAL TOOL 8435
29. Remove the timing chain tensioner plug from engine block. Remove oil reservoir cap and timing chain tensioner. (Scheme 51) 1 - PLUG WITH SEAL RING 2 - OIL RESERVOIR CAP 3 - TIMING CHAIN TENSIONER NOTE: The design of the timing chain cover will allow the timing chain to stay on the crankshaft sprocket without skipping any teeth. Do not rotate engine.
30. Remove camshaft sprocket from camshaft. Partially lower camshaft sprocket to allow timing chain to be removed from camshaft sprocket. Allow timing chain to fall into crankcase.
31. Remove cylinder head plugs. Remove fasteners holding timing chain guides to cylinder head. Remove timing chain guides. (Scheme 52) 1 - RIGHT TIMING CHAIN GUIDE (MOVABLE) 2 - LEFT TIMING CHAIN GUIDE (FIXED) 3 - FASTENER(S) 4 - CYLINDER HEAD PLUG(S) CAUTION: Avoid damaging spark plug tubes when removing cylinder head bolts.
32. Remove cylinder head bolts. (Scheme 53)
33. Remove cylinder head and gasket.

Scheme 53

CLEANING

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Note. Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Remove all gasket material from cylinder head and block (Refer to ENGINE - STANDARD PROCEDURE) . Be careful not to gouge or scratch the aluminum head sealing surface.

Clean all engine oil passages.

Scheme 54

1. Cylinder head must be flat within 0.1 mm (0.004 in.). (Scheme 54) 1 - FEELER GAUGE 2 - STRAIGHT EDGE
2. Inspect camshaft bearing journals for scoring.
3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
4. Using a small hole gauge and a micrometer, measure valve guides in 3 places top, middle and bottom. (Scheme 55) «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine). Replace cylinder head if they are not within specification.

Scheme 55

INSTALLATION - CYLINDER HEAD

Note. The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolt(s) should be replaced. (Scheme 56)

Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt(s) should be replaced.

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

1. Clean the cylinder head and cylinder block sealing surfaces «(Refer to ENGINE/CYLINDER HEAD - CLEANING)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine__cleaning).
2. Position a new cylinder head gasket on the locating dowels.
3. Position the cylinder head onto the engine block. Make sure the cylinder head seats fully over the locating dowels. CAUTION: Avoid damaging spark plug tubes when installing/torquing cylinder head bolts.
4. Before installing cylinder head bolts, the threads should be oiled with engine oil.
5. Tighten the cylinder head bolts in the sequence (Scheme 57) Using the 4 step torque method, tighten according to the following values: Step One: Tighten the ten M10 bolts to 20 N.m (15 ft. lbs.) Tighten the two M8 bolts to 15 N.m (11 ft. lbs.) Step Two: Tighten the ten M10 bolts to 41 N.m (30 ft. lbs.) Step Three: Recheck the ten M10 bolts to 41 N.m (30 ft. lbs.) Step Four: Do not use a torque wrench for this step. Tighten the ten M10 bolts an additional 90 degrees Tighten the two M8 bolts to 30 N.m (22 ft. lbs.)
6. Install timing chain guides. Torque fasteners to 28 N.m (250 in. lbs.). (Scheme 52)
7. Retrieve timing chain from crankcase with a magnet or fabricated hook.
8. Align triangular timing mark on cam sprocket with the timing chain link that was painted during disassembly. Install timing chain on cam sprocket. (Scheme 49)
9. Install camshaft sprocket on the camshaft. 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.
10. Install camshaft sprocket bolt. While holding the camshaft sprocket with Special Tool 8435, torque bolt to 115 N.m (85 ft. lbs.). (Scheme 50) 1 - CHECK BALL 2 - PLUG WITH SEAL RING 3 - OIL RESERVOIR CAP 4 - TIMING CHAIN TENSIONER
11. Reset the timing chain tensioner using the following method: Remove oil reservoir cap from timing chain tensioner. (Scheme 58) Place tensioner on a clean flat surface. Place your palm against the tensioner and press down on the tensioner with continuous pressure until the fully extended tensioner bottoms out. (Scheme 59) Install oil reservoir cap onto timing chain tensioner. (Scheme 58)
12. Install timing chain tensioner with oil reservoir cap into engine block. (Scheme 51)
13. Install timing chain tensioner plug with seal ring. Torque plug to 62 N.m (46 ft. lbs.). CAUTION: Do not pry directly on chain. Damage to timing chain may occur.
14. Using a long thin screwdriver, pry in on the right (movable) timing chain guide until the timing chain tensioner ratchets out to tension the chain. (Scheme 60) NOTE: Ensure the timing chain is properly positioned within the channel of the timing chain guides.
15. Install cylinder head plugs. Torque to 18 N.m (162 in. lbs.). (Scheme 52)
16. Install cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) ).
17. Install camshaft position sensor. Torque fastener to 10 N.m (85 in. lbs.). Reconnect connector.
18. Install right engine mount bracket «(Refer to ENGINE/ENGINE MOUNTING/ENGINE MOUNT BRACKET - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
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 reservoir 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 COOLING/ENGINE - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
40. Perform torque strut adjustment procedure «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).

Scheme 61

1. Disconnect the 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. Disconnect make-up air hose and PCV hoses from cylinder head cover. (Scheme 61)
4. Disconnect the ignition coil and capacitor electrical 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. (Scheme 62)

Scheme 62

Clean cylinder head and cover mating surfaces using a suitable solvent.

INSPECTION

Inspect cover rails for flatness.

Scheme 63

Scheme 64

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 67

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

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 70

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 73

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

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. 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

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 77

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

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

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

STANDARD PROCEDURE - VALVE AND VALVE SEAT REFACING

For all applicable valve and seat dimensions and angles (Refer to ENGINE - SPECIFICATIONS) .

Scheme 82

Scheme 83

1. Reface valves using a suitable valve refacing machine.
2. Inspect the remaining margin after the valves are refaced. (Scheme 82) Intake valves with less than 0.79 mm (0.0312 in.) margin and exhaust valves with less than 1.19 mm (0.0469 in.) margin should be replaced. 1 - VALVE FACE 2 - VALVE MARGIN
3. Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced.
4. Reface valve seats using a suitable valve seat machine
5. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones or cutter. A true and complete surface must be obtained.
6. Measure the concentricity of valve seat and valve guide using a valve seat runout dial indicator. Total runout should not exceed. 0.051 mm (0.002 in.) (total indicator reading).
7. Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of the valve face, lower valve seat with a 15 degrees stone/cutter. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone/cutter.
8. When seat is properly positioned the width of intake and exhaust seats should be 0.75-1.25 mm (0.029-0.049 in.). (Scheme 83) 1 - SEAT WIDTH 2 - FACE ANGLE 3 - SEAT ANGLE 4 - SEAT CONTACT AREA
9. Check valve tip to cylinder head surface dimensions after machining the valve seats or faces. Grind valve tip until within specifications. Measure from valve tip to cylinder head surface when valve is installed in the head (measurement A). (Scheme 84) For valve tip specifications, «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine). The valve tip chamfer is needed to be reground to prevent seal damage when the valve is installed.
10. Measure valve spring installed height (measurement B). (Scheme 84) Measure from the top of the valve spring seat/seal to the bottom of the valve spring retainer. For valve spring installed height specifications, «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).

Scheme 84

The cast iron engine block is a two-piece assembly, consisting of the engine block and bed plate. (Scheme 85) The bed plate incorporates the main bearing caps and bolts to the engine block. This design offers a much stronger lower end and increased engine block rigidity. The rear oil seal retainer is integral with the block. The bed plate and block are serviced as an assembly.

Scheme 85

Scheme 86

1. Used carefully, the cylinder bore resizing hone, recommended tool C-823 or equivalent, equipped with 220 grit stones, is the best tool for this honing procedure. In addition to deglazing, it will reduce taper and out-of-round as well as removing light scuffing, scoring or scratches. Usually a few strokes will clean up a bore and maintain the required limits.
2. Deglazing of the cylinder walls may be done using a cylinder surfacing hone, recommended tool C-3501 or equivalent, equipped with 280 grit stones, if the cylinder bore is straight and round. 20-60 strokes depending on the bore condition, will be sufficient to provide a satisfactory surface. Use a light honing oil. Do not use engine or transmission oil, 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 seating of rings. (Scheme 86) 1 - CROSS-HATCH PATTERN 2 - 40°-60°
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.

Clean cylinder block thoroughly using a suitable cleaning solvent.

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 ENGINE - STANDARD PROCEDURE - ENGINE CORE AND OIL GALLERY PLUGS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) .
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. (Scheme 87)(Refer to ENGINE - SPECIFICATIONS). If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.

Scheme 87

Measure the cylinder bore at three levels in directions A and B. (Scheme 87) 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 ENGINE - SPECIFICATIONS).

Note. The upper and lower main bearing shells are NOT interchangeable.

The crankshaft is supported by five main bearings. All upper bearing shells in the crankcase have oil grooves/oil feed holes. All lower bearing shells installed in the (bed plate) main bearing cap are plain. Crankshaft end play is controlled by a flanged bearing on the number three upper main bearing journal. (Scheme 88)

Scheme 88

The crankshaft is made of nodular cast iron and includes five main bearing journals and four connecting rod journals. (Scheme 89) The number three journal is the location for the thrust bearing. The crankshaft utilizes a replaceable tonewheel for crankshaft position sensor function.

Scheme 89

Scheme 90

1. Mount a dial indicator to front of engine, locating probe on nose of the crankshaft. (Scheme 90)
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 of its travel and read the dial indicator. For crankshaft specifications «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).

Scheme 91

1. Remove engine assembly from vehicle «(Refer to ENGINE - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine__removal).
2. Separate transaxle from engine.
3. Remove clutch and pressure plate. Remove flywheel.
4. Remove crankshaft rear oil seal «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
5. Mount engine on a suitable repair stand.
6. Remove the right engine mount bracket «(Refer to ENGINE/ENGINE MOUNTING/ENGINE MOUNT BRACKET - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
7. Remove crankshaft vibration damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
8. Remove the timing chain «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
9. Remove the intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
10. Remove the oil dipstick tube.
11. Remove oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
12. Remove oil pump pick-up tube. (Scheme 91) 1 - FASTENERS 2 - OIL PUMP PICK-UP 3 - O-RING
13. Remove crankshaft position sensor.
14. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
15. 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.
16. Remove all main bearing cap and bed plate bolts from the engine block. (Scheme 85)
17. Using a mallet tap the bed plate 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 and bed plate alignment.
18. Bed plate should be removed evenly from the cylinder block dowel pins.
19. Lift out crankshaft from cylinder block. Be sure not to damage the main bearings or journals when removing the crankshaft.

The crankshaft journals should be checked for excessive wear, taper and scoring. (Scheme 92) 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.

Scheme 92

The upper number three bearing half is flanged to carry the crankshaft thrust load and is NOT interchangeable with any other bearing halves in the engine. see scheme 96 All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation.

Scheme 93

Scheme 94

1. Install the upper main bearing shells with the lubrication groove in the cylinder block. see scheme 96
2. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. 1 - UPPER CRANKSHAFT MAIN BEARINGS 2 - THRUST BEARING 3 - LOWER CRANKSHAFT MAIN BEARINGS 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.
3. Oil the bearings and journals and install crankshaft in cylinder block. CAUTION: Use only the specified anaerobic sealer on the bed plate or damage may occur to the engine.
4. Apply 1.5-2.0 mm (0.059-0.078 in.) bead of Mopar® Bed Plate Sealant to bed plate (Scheme 93)
5. 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 bearing/bed plate onto engine block.
6. Before installing the main bearing cap/bed plate bolts, oil threads with clean engine oil, wipe off any excess oil.
7. Install and finger tighten the main bearing cap bolts.
8. Install and finger tighten the bed plate bolts.
9. Snug the three bed plate bolts at the dowel locations (bolts 11, 17, and 20) to bring the bed plate down to the block. (Scheme 94)
10. Snug the remaining main bearing cap/bed plate bolts.
11. Torque the main bearing cap /bed plate bolts to the sequence (Scheme 94)to the following torque: Main Bearing Cap Bolts - 61 N.m (45 ft. lbs.) Bed plate Bolts - 30 N.m (22 ft. lbs.)
12. After the main bearing bed plate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 N.m (50 in. lbs.).
13. Check crankshaft end play «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
14. Install connecting rod bearings and caps. Install new connecting rod bolts and tighten to 26 N.m (19 ft. lbs.) plus 1/4 turn.
15. Install oil pick-up tube. (Scheme 91)
16. Install the oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
17. Install the oil dipstick tube.
18. Install the intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
19. Install the timing chain «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
20. Install the right engine mount bracket «(Refer to ENGINE/ENGINE MOUNTING/ENGINE MOUNT BRACKET - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
21. Remove engine from repair stand and position on Special Tools 6135 and 6710 Engine Dolly and Cradle. Install safety straps around the engine to cradle and tighten and lock them into position.
22. Install the crankshaft rear oil seal. «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine)
23. Install flywheel. Install clutch and pressure plate.
24. Install the transaxle to engine.
25. Install the engine assembly «(Refer to ENGINE - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine__installation).

1. Remove timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN COVER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) .
2. Using a suitable tool, drive the front crankshaft oil seal out of the timing chain cover from the back side.

1. Install front crankshaft oil seal into timing cover using Special Tool 6780.
2. Install timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN COVER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) .

1. Remove transaxle «(Refer to TRANSMISSION/TRANSAXLE/MANUAL - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/manual-trans/#g288-manual-transmission-overhaul__removal) or «(Refer to TRANSMISSION/TRANSAXLE/MANUAL - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/manual-trans/#t350-manual-transmission-overhaul__removal).
2. Remove clutch and pressure plate.
3. Remove flywheel.
4. Insert a 3/16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal. Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal. (Scheme 95)

Scheme 95

Scheme 96

1. Place Special Tool 6926-1 on crankshaft. This is a pilot tool with a magnetic base. (Scheme 96)
2. Position seal over pilot tool. Pilot tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation. CAUTION: If the seal is driven into the block past flush, an oil leak may result.
3. Drive the seal into the block using Special Tool 6926-2 and handle C-4171 until the tool bottoms out against the block. (Scheme 96) 1 - REAR CRANKSHAFT OIL SEAL 2 - SPECIAL TOOL 6926-1 PILOT 3 - SPECIAL TOOL 6926-2 INSTALLER 4 - SPECIAL TOOL C-4171 DRIVE HANDLE
4. Install flywheel.
5. Install clutch and pressure plate.
6. Install transaxle «(Refer to TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/manual-trans/#g288-manual-transmission-overhaul__installation) or «(Refer to TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/manual-trans/#t350-manual-transmission-overhaul__installation).

Note. The engine DOES NOT have provisions for a free wheeling valve train. Non free wheeling valve train means, in the event of a broken timing chain, pistons will contact the valves.

The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged powdered metal connecting rods. The connecting rods are a cracked cap design and are not repairable. Hex head cap screws are used to provide alignment and durability in the assembly. The pistons and connecting rods are serviced as an assembly.

Scheme 97

1. Measure connecting rod bearing clearance using Plastigage. (Scheme 97) For more information on use of Plastigage «(Refer to ENGINE - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine). Refer to Engine Specifications for connecting rod specifications. «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) CAUTION: Do not rotate crankshaft or the Plastigage may be smeared. NOTE: The rod bearing bolts should not be reused.
2. Before installing NEW bolts, lubricate the threads with clean engine oil.
3. Install each bolt finger tight than alternately torque each bolt to assemble the cap properly.
4. Tighten the bolts to 26 N.m PLUS 1/4 turn (19 ft. lbs. PLUS 1/4 turn) Do not use a torque wrench for last step.
5. Using a feeler gauge, check connecting rod side clearance. (Scheme 98) Refer to Engine Specifications for connecting rod specifications. «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine)

Scheme 98

CYLINDER BORE AND PISTON - FITTING

Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin about 14 mm (9/16 inch.) from the bottom of the skirt (Scheme 100) Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location B) to the engine crankshaft center line (Scheme 99) (Refer to ENGINE - SPECIFICATIONS). Correct piston to bore clearance must be established in order to assure quiet and economical operation.

Note. Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C).

Scheme 99

Scheme 100

Scheme 101

1. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
2. Using a permanent ink marker or scribe tool mark the cylinder number on the side of the rod and cap for identification. (Scheme 101)
3. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore.
4. Remove connecting rod cap bolts Do not use old bolts if reinstalling connecting rod.
5. To protect crankshaft journal and fractured rod surfaces, install Special Tool 8388, connecting rod guides onto connecting rod. (Scheme 102) Carefully push each piston and rod assembly out of cylinder bore. CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage many occur.
6. Remove Special Tool 8388, connecting rod guides and re-install bearing cap on the mating rod.

Note. Piston and rods are serviced as an assembly.

Scheme 102

1. Install piston rings on piston «(Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
2. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil.
3. Install connecting rod bearing half onto connecting rod.
4. Install Special Tool 8388 connecting rod guides onto connecting rod. (Scheme 103)
5. Before installing pistons and connecting rod assemblies into the bore, ensure the compression ring gaps are staggered, and neither is in line with the oil ring rail gap. Ensure the oil ring expander ends are butted and the rail gaps are staggered.
6. Immerse the piston head and rings in clean engine oil, slide the ring compressor over the piston. Be sure position of rings does not change during this operation.
7. Compress piston rings.
8. Install piston into cylinder making sure marks on piston face toward front of engine. (Scheme 103)
9. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
10. Remove Special Tool 8388, connecting rod guides.
11. Install connecting rod lower bearing half and cap. Install New bolts and tighten to 26 N.m (19 ft. lbs.) plus 1/4 turn. CAUTION: Do not use a torque wrench for the second step.

Scheme 103

Scheme 104

Scheme 105

1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioned below normal ring travel in the cylinder bore. Check gap with feeler gauge. (Scheme 104) For piston ring specifications «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine). 1 - FEELER GAUGE 1 - FEELER GAUGE
2. Check piston ring to groove side clearance. (Scheme 105) For piston ring specifications «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).

Scheme 106

1. Using a suitable ring expander, remove upper and intermediate piston rings. (Scheme 106)
2. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston.
3. Clean ring grooves of any carbon deposits.

Install rings with manufacturers identification mark facing up, to the top of the piston. (Scheme 107)

Scheme 107

1. Oil ring expander.
2. Upper oil ring side rail.
3. Lower oil ring side rail.
4. No. 2 Intermediate piston ring.
5. No. 1 Upper piston ring.

Scheme 108

1. Install oil ring expander. (Scheme 107)
2. Install upper side rail first and then the lower side rail. Install the side rails by placing one end between the piston ring groove and the oil ring expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander. (Scheme 108) 1 - SIDE RAIL END
3. Install No. 2 piston ring and then No. 1 piston ring. (Scheme 107)
4. Position piston ring end gaps (Scheme 109)
5. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control.

Scheme 109

1. Disconnect negative battery cable.
2. Raise vehicle on hoist.
3. Remove the right wheel and accessory drive belt splash shield.
4. Remove accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system__removal).
5. Remove crankshaft vibration damper bolt. Remove damper using Special Tool 1026 puller and 6827A insert. (Scheme 110)

Scheme 110

1. Install crankshaft vibration damper using Special Tool 8385 installer. (Scheme 111)
2. Install vibration damper bolt. Tighten bolt to 115 N.m (85 ft. lbs.).
3. Install the accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system__installation).
4. Install the accessory drive belt splash shield and right wheel.
5. Lower the vehicle.
6. Connect negative battery cable.

Scheme 111

The engine mounting system consists of a four-point system utilizing two load-carrying mounts and two torque struts. The load-carrying mounts are located on each frame rail. The right mount is a hydro-elastic mount and left mount is a conventional elastomeric isolator. The two torque controlling struts are attached at the front of the engine, straddling the right side load-carrying mount. The upper torque strut connects to the suspension strut tower and the lower torque strut connects to the suspension crossmember.

UPPER TORQUE STRUT

1. Remove bolts attaching strut to shock tower bracket and engine mount bracket. (Scheme 11)
2. Remove the upper torque strut.

LOWER TORQUE STRUT

1. Raise vehicle on hoist.
2. Remove accessory drive belt splash shield.
3. Remove pencil strut. see scheme 117
4. Remove bolts attaching lower strut to crossmember and strut bracket. (Scheme 11)and see scheme 117.
5. Remove lower torque strut.

1. Position the upper torque strut into mounting locations. (Scheme 11)
2. Install the mounting bolts.
3. Perform torque strut adjustment procedure «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).

1. Position lower torque strut into mounting locations. (Scheme 11)
2. Install mounting bolts.
3. Install pencil strut. see scheme 117
4. Perform torque strut adjustment procedure «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
5. Install accessory drive belt splash shield.
6. Lower vehicle.

ADJUSTMENT

The upper and lower torque struts need to be adjusted together to assure proper engine positioning and engine mount loading. Whenever a torque strut bolt(s) is loosened, this procedure must be performed.

Scheme 112

Scheme 113

1. Loosen the upper and lower torque strut attaching bolt at the suspension crossmember and shock tower bracket.
2. The engine position may now be adjusted by positioning a suitable floor jack on the forward edge of the transmission bell housing. (Scheme 112) NOTE: The floor jack must be positioned as shown in to prevent minimal upward lifting of the engine. (Scheme 112)
3. With the engine supported, remove the upper and lower torque strut attachment bolt(s) at shock tower bracket and suspension crossmember. (Scheme 11) Verify that the torque struts are free to move within the shock tower bracket and crossmember. Reinstall the torque strut bolt(s), but do not tighten. 1 - WOOD BLOCK 2 - FLOOR JACK
4. Carefully apply upward force, allowing the upper engine to rotate rearward until the distance between the center of the rearmost attaching stud on the engine mount bracket (point "A") and the center of the hole for the washer hose clip on the shock tower bracket (point "B") is 119 mm (4.70 in.). (Scheme 113)
5. With the engine held at the proper position, tighten both the upper and lower torque strut bolts to 118 N.m (87 ft. lbs.). (Scheme 11)
6. Remove the floor jack.

1. Remove upper torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
2. Remove fasteners securing power steering reservoir bracket to right engine mount bracket.
3. Remove fastener securing power steering return line to right engine mount bracket.
4. Raise vehicle on hoist.
5. Remove right front wheel.
6. Remove accessory drive belt splash shield.
7. Remove lower torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
8. Remove lower right engine mount bracket bolt.
9. Lower vehicle.
10. Support engine with floor jack and wooden block on oil pan.
11. Remove access cover in right frame rail for right engine mount through bolt.
12. Remove right engine mount through bolt.
13. Raise engine with floor jack.
14. Remove remaining bolts and studs for right engine mount bracket. Remove bracket. (Scheme 114)

Scheme 114

1. Install right engine mount bracket. Hand start all fasteners. Torque M10 bolts to 68 N.m (50 ft. lbs.). Torque M12 studs to 118 N.m (87 ft. lbs.). (Scheme 114)
2. Lower engine enough to install right engine mount through bolt.
3. Install right engine mount through bolt. Torque bolt to 118 N.m (87 ft. lbs.).
4. Install access cover in right side frame rail.
5. Remove floor jack and wooden.
6. Raise vehicle on hoist.
7. Install lower torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
8. Install accessory drive belt splash shield.
9. Install right front wheel.
10. Lower vehicle.
11. Install fastener securing power steering return line to right engine mount bracket.
12. Install fasteners securing power steering reservoir bracket to right engine mount bracket.
13. Install upper torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).

1. Remove right engine mount bracket «(Refer to ENGINE/ENGINE MOUNTING/ENGINE MOUNT BRACKET - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine). NOTE: The right engine mount attaching holes are slightly oversize to compensate for manufacturing tolerances. The mount has been set at the manufacturing plant for proper powertrain alignment. Therefore, it is necessary to mark the position of the mount before the attaching bolts are loosened.
2. Using a permanent ink marker or equivalent, mark the position of engine mount to the body frame rail.
3. Remove bolts attaching mount to body. (Scheme 115)
4. Remove mount between engine and body frame rail.

Scheme 115

1. Position the mount into the original position on body frame rail. (Scheme 115) NOTE: Engine mount must be installed in the original position on body frame rail. If mount was not marked or frame rail was replaced, perform the following procedure.
2. Perform the following procedure if mount position was not previously marked or the frame rail was replaced: Insert the new mount loosely in frame rail. Align the four holes in the mount with the mating holes in the rail such that the holes are concentric (frame rail holes centered in the mount holes). Using a permanent ink marker or equivalent, mark the position of engine mount to the body frame rail while maintaining mounting hole concentricity.
3. Ensure the mount maintains originally marked position and install mount bolts. Tighten bolts to 28 N.m (250 in. lbs.). (Scheme 115)
4. Install right engine mount bracket «(Refer to ENGINE/ENGINE MOUNTING/ENGINE MOUNT BRACKET - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
5. Remove the support from under engine.

1. Remove air cleaner assembly.
2. Disconnect negative cable from battery.
3. Remove bolts attaching the power distribution center (PDC) bracket to left mount and battery tray. see scheme 122
4. Support transaxle with a suitable jack.
5. Remove mount to transaxle bolts. (Scheme 116)
6. Remove left mount bracket to body frame rail fasteners. (Scheme 116)
7. Remove mount.

Scheme 116

1. Install engine mount bracket to body frame rail and tighten fasteners to 28 N.m (250 in. lbs.). (Scheme 116)
2. Position engine/transaxle for installation of mount to transaxle bolts. Install and tighten bolts to 68 N.m (50 ft. lbs.). (Scheme 116)
3. Remove jack from under transaxle.
4. Install bolts attaching the power distribution center (PDC) bracket to left mount and battery tray. see scheme 122
5. Connect negative cable to battery.
6. Install air cleaner assembly.

The lubrication system is a full-flow filtration, pressure feed type. The oil pump is incorporated into the timing chain cover and driven by the crankshaft. Oil pressure is controlled by a relief valve mounted inside the oil pump housing. (Scheme 117)

Scheme 117

OPERATION

Engine oil is drawn up through the pickup tube and is pressurized by the oil pump and routed through the oil filter to the main oil gallery running the length of the cylinder block. A diagonal hole in each bulkhead feeds oil to each main bearing. Drilled passages within the crankshaft route oil from the main bearing journals to the connecting rod journals. The main oil gallery also feeds oil pressure to the timing chain tensioner. A vertical hole at the number three main bearing area routes pressurized oil through a restrictor up into the cylinder head. The restrictor that is integral to the cylinder head gasket, provides increased oil flow to the main gallery. Upper engine lubrication is provided by one main feed to the number three camshaft bearing cap. Oil is then routed through the rocker shafts to the remaining camshaft bearing caps and rocker arms/hydraulic lash adjusters. Oil returning to the oil pan from the pressurized components supplies lubrication to the valve stems. The cylinder bores and wrist pins are splash lubricated from directed slots on the connecting rod thrust collar. (Scheme 118)

Scheme 118

CHECKING ENGINE OIL PRESSURE

Check oil pressure using a gauge at oil pressure switch location.

1. Remove pressure sending unit. The pressure sending unit is located on the oil filter cartridge housing. (Scheme 119)
2. Install oil pressure test gauge, Special Tool C-3292 with Adapter 8406. For Special Tool identification, «(Refer to ENGINE - SPECIAL TOOLS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine). CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM.
3. Warm engine to normal operating temperature.
4. Monitor gauge readings at idle and 3000 rpm. For specifications «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).

Scheme 119

1. Turn oil filter cap counterclockwise 2 1/2 turns and wait one minute. (Scheme 120) NOTE: A drain back valve incorporated into the oil filter cartridge housing allows oil to drain back into the crankcase as the oil filter cartridge is removed. (Scheme 120)
2. Continue turning the oil filter cap counterclockwise. Remove cap slowly to avoid spill of oil.
3. Remove oil filter cartridge from the cap. (Scheme 120) NOTE: If the center tube separates from the cap and stays inside the filter cartridge, you must remove the center tube from the filter element and snap it back onto the cap with the spring. (Scheme 120)
4. Remove and discard o-ring from cap.

Scheme 120

1. Install new o-ring on cap. (Scheme 120)
2. Install new oil filter cartridge over center tube of cap. (Scheme 120) NOTE: Before installation, make sure no grommet is left on the center post of the oil filter housing from the previous filter. (Scheme 120)
3. Align the grommet hole of the oil filter cartridge with the center post of the filter housing.
4. Press in and turn oil filter cap clockwise. Tighten cap to 25 N.m (18 ft. lbs). Cap flange should sit tightly on the housing flange.
5. Fill oil to proper level.
6. Start engine. Check for leaks.

The oil filter cartridge housing is attached to the right side of the engine utilizing a seal between the housing and engine block. The housing contains an oil filter cartridge that cleans the engine oil coming from the oil pump prior to it entering the main engine oil gallery. The oil pressure switch is used to provide the driver with engine oil pressure information. (Scheme 121)

Other components of the oil filter cartridge housing. (Scheme 121)

1. By-Pass Valve: If the oil filter cartridge becomes plugged, this valve opens allowing unfiltered oil to enter the main engine oil gallery.
2. Inlet Check Valve: This valve opens when engine oil pressure pushes against it. After the engine is shut off, the valve closes allowing oil to remain in the oil filter cartridge housing.
3. Drainback Valve: With the oil filter cartridge installed, this valve is closed. As the oil filter cap and oil filter cartridge are removed, the valve opens allowing the reserve of oil in the cartridge housing to drain back into the engine oil pan.

Scheme 121

1. Raise vehicle on hoist.
2. Disconnect oil pressure switch electrical connector.
3. Remove oil filter cartridge «(Refer to ENGINE/LUBRICATION/OIL FILTER CARTRIDGE - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) .
4. Remove fasteners securing oil filter cartridge housing to engine block.
5. Remove oil filter cartridge housing.

1. Inspect and clean oil filter cartridge housing sealing surfaces.
2. Replace oil filter cartridge housing seal. see scheme 129
3. Install oil filter cartridge housing mounting fasteners. Torque fasteners to 28 N.m (250 in. lbs.).
4. Install oil filter cartridge «(Refer to ENGINE/LUBRICATION/OIL FILTER CARTRIDGE - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
5. Connect oil pressure switch electrical connector.
6. Lower vehicle.
7. Start engine. Check for leaks.
8. Turn engine off. Check oil level. Fill oil to proper level.

Scheme 122

Scheme 123

Scheme 124

1. Disconnect negative battery cable.
2. Raise vehicle on hoist.
3. Remove right front wheel.
4. Remove accessory drive belt splash shield.
5. Drain engine oil.
6. Remove air conditioning compressor lower bracket. (Scheme 122)
7. Remove bolt attaching lower torque strut to oil pan bracket. (Scheme 123)
8. Remove clutch slave cylinder and reposition. (Scheme 124)
9. Remove oil pan fasteners.
10. Remove oil pan.

Scheme 125

Scheme 126

1. Clean oil pan and all sealing surfaces.
2. Position new oil pan gasket onto pan.
3. Install oil pan. (Scheme 125)
4. Install oil pan fasteners and tighten in sequence. (Scheme 126) Torque bolts to 31 N.m (275 in. lbs.).
5. Install the clutch slave cylinder. (Scheme 124)
6. Install air conditioning compressor lower bracket. (Scheme 123)
7. Install accessory drive belt splash shield.
8. Install right front wheel.
9. Lower vehicle.
10. Fill engine crankcase with the proper oil to correct level. Refer to «LUBRICATION & MAINTENANCE»(/chrysler/pt-cruiser/i-2000-2010/remont/hoistjack/#lubrication-maintenance) for oil capacity and type.
11. Connect negative battery cable.

1. Remove timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN COVER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) .

1. Install timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN COVER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) .

1. Remove oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
2. Remove fasteners securing oil pump pick-up to engine block. see scheme 135
3. Remove oil pump pick-up.

1. Clean sealing surfaces.
2. Replace o-ring. see scheme 135
3. Install oil pump pick-up. Torque fasteners to 12 N.m (105 in. lbs.).
4. Install oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).

UPPER INTAKE MANIFOLD

1. Disconnect negative battery cable.
2. Disconnect throttle body air inlet hose and purge solenoid vacuum hose from throttle body. (Scheme 127)
3. Disconnect PCV hose from upper intake manifold. (Scheme 127)
4. Disconnect brake booster vacuum hose.
5. Disconnect electronic throttle control motor electrical connector.
6. Remove upper intake manifold support bracket fasteners. (Scheme 127)
7. Remove upper intake manifold fasteners. (Scheme 127)
8. Remove upper intake manifold and gasket.

Scheme 127

LOWER INTAKE MANIFOLD

1. Perform fuel pressure release procedure «(Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/fuel-system/#fuel-system).
2. Disconnect negative battery cable.
3. Remove upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
4. Disconnect fuel line from fuel rail.
5. Disconnect fuel injector electrical connectors.
6. Remove fuel rail.
7. Remove lower intake manifold mounting bolts.
8. Remove lower intake manifold. (Scheme 128)

Scheme 128

1. Position the upper intake manifold and gasket.
2. Install upper intake manifold fasteners. Tighten to 12 N.m (105 in. lbs.).
3. Install upper intake manifold support bracket fasteners. (Scheme 127) Tighten M6 fasteners to 19 N.m (165 in. lbs.) and M8 fasteners to 28 N.m (250 in. lbs.).
4. Connect PCV hose to upper intake manifold. (Scheme 127)
5. Connect brake booster vacuum hose.
6. Connect electronic throttle control motor electrical connector.
7. Connect throttle body air inlet hose and purge solenoid vacuum hose to throttle body. (Scheme 127)
8. Connect negative battery cable.

1. Clean manifold sealing surfaces.
2. Inspect and replace intake manifold seals as necessary.
3. Position lower intake manifold.
4. Install lower intake manifold mounting bolts. Tighten bolts to 26 N.m (230 in. lbs.). (Scheme 128)
5. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
6. Insert fuel injector nozzles into openings in lower intake manifold. Seat the injectors in place. Install fuel rail fasteners. Tighten fuel rail mounting fasteners to 22.5 N.m +/- 3 N.m (200+/-30 in. lbs.).
7. Connect fuel injector electrical connectors.
8. Connect fuel line to fuel rail.
9. Install upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
10. Connect negative battery cable.

Scheme 129

1. Disconnect negative battery cable.
2. Disconnect ignition coil and capacitor electrical connectors.
3. Remove ignition coil and plug wires «(Refer to ELECTRICAL/IGNITION CONTROL/IGNITION COIL - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/ignition-system/#ignition-control).
4. Raise vehicle on hoist.
5. Disconnect exhaust pipe from exhaust manifold.
6. Remove starter heat shield bolt. (Scheme 129)
7. Lower vehicle.
8. Remove exhaust manifold upper heat shield bolts and remove heat shield.
9. Remove exhaust manifold bolts and remove manifold.

1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head.

1. Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length.
2. Inspect manifolds for cracks or distortion. Replace manifold as necessary.

Scheme 130

1. Clean gasket surfaces.
2. Install exhaust manifold with a new gasket and install bolts to hold gasket in place. (Scheme 130) The gasket has tabs in the bolt holes to retain the exhaust manifold bolts for installation purposes.
3. Tighten the exhaust manifold bolts in a spiral pattern starting with the center bolts and working outward. Tighten bolts to 23 N.m (200 in. lbs.).
4. Install exhaust manifold upper heat shield and tighten bolts to 28 N.m (250 in. lbs.).
5. Raise vehicle on hoist.
6. Install the starter heat shield bolt. (Scheme 129)
7. Install the exhaust pipe to the exhaust manifold. Tighten bolts to 28 N.m (250 in. lbs.).
8. Lower vehicle.
9. Install ignition coil and spark plug cables «(Refer to ELECTRICAL/IGNITION CONTROL/IGNITION COIL - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/ignition-system/#ignition-control).
10. Connect ignition coil and capacitor electrical connector.
11. Connect negative battery cable.

The timing drive system consists of the following. (Scheme 131)

1. Timing Chain
2. Camshaft Sprocket
3. Crankshaft Sprocket
4. Right Timing Chain Guide (Movable)
5. Left Timing Chain Guide (Fixed)
6. Timing Chain Tensioner/Oil Reservoir Cap/Plug with Seal Ring

The camshaft sprocket is attached to the front of the camshaft and is used with the timing chain and crankshaft sprocket to turn the camshaft. The camshaft position sensor target is part of the sprocket and is used with the camshaft position sensor to provide the PCM with valvetrain position information.

The timing chain tensioner is installed in the right side of the engine block. Using engine oil pressure, the tensioner applies constant pressure to the right side (movable) timing chain guide, which in turn applies pressure to the timing chain. Also as the tensioner extends, it ratchet locks in position to provide constant timing chain tension. An oil reservoir cap attaches to the timing chain tensioner to provide an available "pocket" of oil to the tensioner during initial start up.

Scheme 131

VALVE TIMING VERIFICATION

1. Remove cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
2. Remove number one spark plug.
3. Using a dial indicator, set number one cylinder to TDC on the compression stroke.
4. The mark on the camshaft sprocket should be in line with the cylinder head cover sealing surface. (Scheme 132)
5. Using a suitable light, look down into the timing chain cavity at the crankshaft sprocket. A paint mark on the crankshaft sprocket should align with the edge of the engine block boss indicated in. (Scheme 133)
6. Install cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) ).

Scheme 132

Scheme 133

1. Disconnect and isolate the negative battery cable.
2. Remove the power steering reservoir bracket bolts «(Refer to STEERING/PUMP/RESERVOIR - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/manual-power-steering/#steering-system).
3. Partially drain the cooling system and disconnect the upper radiator hose at the radiator.
4. Remove the radiator cooling fan «(Refer to COOLING/ENGINE/RADIATOR FAN - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
5. Raise vehicle on hoist.
6. Remove the right front wheel.
7. Remove the accessory drive belt splash shield.
8. Remove the accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system__removal).
9. Remove the crankshaft vibration damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
10. Remove the accessory drive belt tensioner «(Refer to COOLING/ACCESSORY DRIVE/BELT TENSIONERS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
11. Remove the accessory drive belt idler pulley «(Refer to COOLING/ACCESSORY DRIVE/IDLER PULLEY - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
12. Remove the air conditioning compressor mounting bolts and position compressor out of the way. Do Not disconnect lines from air conditioning compressor. Support air conditioning compressor with suitable strap.
13. Remove the power steering pump/water pump mounting bolts and position pump out of the way.
14. Remove the timing cover bolts. Note the location of the shoulder bolt(s).
15. Remove the timing cover. (Scheme 134)

Scheme 134

Scheme 135

Scheme 136

1. Clean all sealing surfaces.
2. Replace timing cover seals. see scheme 144 1 - TIMING CHAIN COVER SEALS 2 - OIL PUMP 3 - PRESSURE RELIEF VALVE
3. Apply a 3.2 mm (0.125 in.) bead of Mopar® Engine RTV GEN II at the parting line of the engine block/bedplate (Scheme 135) 1 - 3.2 mm (0.125 in.) BEAD OF RTV AT PARTING LINE 2 - PARTING LINE OF ENGINE BLOCK/BEDPLATE
4. Prime oil pump before installation by filling rotor cavity with engine oil.
5. Align oil pump rotor flats with flats on crankshaft as you install the timing cover to the block. Hand start all fasteners. Torque fasteners in the sequence (Scheme 136)to 12 N.m (105 in. lbs.).
6. Install the power steering/water pump. Tighten bolts to 28 N.m (250 in. lbs.).
7. Install air conditioning compressor. Tighten bolts to 28 N.m (250 in. lbs.).
8. Install the accessory drive belt idler pulley «(Refer to COOLING/ACCESSORY DRIVE/IDLER PULLEY - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
9. Install the accessory drive belt tensioner «(Refer to COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
10. Install the crankshaft vibration damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
11. Install the accessory drive belt «(Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system__installation).
12. Install the accessory drive belt splash shield.
13. Install the right front wheel.
14. Lower vehicle.
15. Install the radiator cooling fan «(Refer to COOLING/ENGINE/RADIATOR FAN - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
16. Connect upper radiator hose.
17. Install the power steering reservoir bracket bolts.
18. Connect the negative battery cable.
19. Fill the cooling system «(Refer to COOLING/ENGINE - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).

TIMING CHAIN AND GUIDES

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 camshaft position sensor.
4. Remove timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN COVER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
5. Rotate crankshaft until number one cylinder is at TDC on compression stroke.
6. Using Special Tool 8435 to hold camshaft sprocket, remove camshaft sprocket bolt. see scheme 147 1 - SPECIAL TOOL 8435
7. Remove the timing chain tensioner plug from engine block. Remove oil reservoir cap and timing chain tensioner. see scheme 148 1 - PLUG WITH SEAL RING 2 - OIL RESERVOIR CAP 3 - TIMING CHAIN TENSIONER
8. Remove right engine mount bracket «(Refer to ENGINE/ENGINE MOUNTING/ENGINE MOUNT BRACKET - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
9. Remove camshaft sprocket from camshaft. Partially lower camshaft sprocket to allow timing chain to be removed from camshaft sprocket.
10. Remove cylinder head plugs. Remove fasteners holding timing chain guides to cylinder head. Remove timing chain guides. see scheme 149 1 - RIGHT TIMING CHAIN GUIDE (MOVABLE) 2 - LEFT TIMING CHAIN GUIDE (FIXED) 3 - FASTENER(S) 4 - CYLINDER HEAD PLUG(S)
11. Remove timing chain. see scheme 154

CAMSHAFT SPROCKET

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. Disconnect and remove the camshaft position sensor.
4. Rotate crankshaft until triangular timing mark on camshaft sprocket is at the 12 o'clock position.
5. For reassembly purposes, paint the timing chain link that lines up with camshaft timing mark. see scheme 150 1 - PAINT THE LINK THAT ALIGNS WITH TIMING MARK 2 - CAMSHAFT SPROCKET TIMING MARK
6. Using Special Tool 8435 to hold camshaft sprocket, remove camshaft sprocket bolt. see scheme 147
7. Remove the timing chain tensioner plug from engine block. Remove oil reservoir cap and timing chain tensioner. see scheme 148
8. Remove camshaft sprocket from camshaft. Partially lower camshaft sprocket to allow timing chain to be removed from camshaft sprocket.

CRANKSHAFT SPROCKET

1. Remove timing chain «(Refer to ENGINE/VALVE TIMING/TIMING CHAIN - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
2. Remove crankshaft sprocket by first installing crankshaft vibration damper bolt. Apply grease or equivalent to damper bolt head and position Special Tools 5048-1, 5048-6, and 8539 on sprocket and crankshaft nose. (Scheme 137)
3. Remove sprocket using care not to rotate the crankshaft.

Scheme 137

1. Install crankshaft sprocket using Special Tools 8385 and 8386. (Scheme 138)
2. Install sprocket using care not to rotate the crankshaft.

Scheme 138

1. Align triangular timing mark on cam sprocket with the timing chain link that was painted during disassembly. Install timing chain on cam sprocket. see scheme 150
2. Install camshaft sprocket on the camshaft. 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.
3. Install camshaft sprocket bolt. While holding the camshaft sprocket with Special Tool 8435, torque bolt to 115 N.m (85 ft. lbs.). see scheme 147
4. Reset the timing chain tensioner using the following method: Remove oil reservoir cap from timing chain tensioner. see scheme 155 Place tensioner on a clean flat surface. Place your palm against the tensioner and press down on the tensioner with continuous pressure until the fully extended tensioner bottoms out. see scheme 156 Install oil reservoir cap onto timing chain tensioner. see scheme 155
5. Install timing chain tensioner with oil reservoir cap into engine block. see scheme 148
6. Install timing chain tensioner plug with seal ring. Torque plug to 62 N.m (46 ft. lbs.). CAUTION: Do not pry directly on chain. Damage to timing chain may occur.
7. Using a long thin screwdriver, pry in on the right (movable) timing chain guide until the timing chain tensioner ratchets out to tension the chain. see scheme 153 NOTE: Ensure the timing chain is properly positioned within the channel of the timing chain guides.
8. Install cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) ).
9. Install camshaft position sensor. Torque fastener to 10 N.m (85 in. lbs.). Reconnect connector.
10. Connect negative battery cable.

Scheme 139

1. Install the left timing chain guide. Torque fastener to 28 N.m ( 250 in. lbs.). see scheme 149
2. Install the right timing chain guide. Torque fastener to 28 N.m ( 250 in. lbs.). see scheme 149 NOTE: When installing the timing chain, ensure the plated links on the timing chain are aligned with the timing marks on the crankshaft and camshaft sprockets. If a timing chain is being re-used, and the plating is wore off the chain, the links also have machined dimples. see scheme 154
3. Feed the timing chain through the opening in the top of the cylinder head.
4. Install the timing chain around the crankshaft sprocket, aligning the two plated links with the crankshaft sprocket timing marks. see scheme 154
5. Install the timing chain around the camshaft sprocket, aligning the single plated link with the camshaft sprocket timing mark. see scheme 154 1 - CAMSHAFT TIMING MARK ALIGNS WITH SINGLE PLATED/DIMPLED LINK 2 - CAMSHAFT SPROCKET 3 - RIGHT TIMING CHAIN GUIDE (MOVABLE) 4 - LEFT TIMING CHAIN GUIDE (FIXED) 5 - PLUG WITH SEAL RING 6 - OIL RESERVOIR CAP 7 - TIMING CHAIN TENSIONER 8 - CRANKSHAFT SPROCKET 9 - TIMING CHAIN 10 - CRANKSHAFT TIMING MARKS ALIGN WITH DOUBLE PLATED/DIMPLED LINKS
6. Install the camshaft sprocket on the camshaft. CAUTION: DO NOT use an impact wrench (or any other air operated tool) for tightening the camshaft sprocket bolt. Damage to the camshaft timing pin can result. ONLY use a hand wrench while holding camshaft sprocket with Special Tool.
7. Install camshaft sprocket bolt. While holding the camshaft sprocket with Special Tool 8435, torque bolt to 115 N.m (85 ft. lbs.). see scheme 147 1 - CHECK BALL 2 - PLUG WITH SEAL RING 3 - OIL RESERVOIR CAP 4 - TIMING CHAIN TENSIONER
8. Reset the timing chain tensioner using the following method: Remove oil reservoir cap from timing chain tensioner. see scheme 155 Place tensioner on a clean flat surface. Place your palm against the tensioner and press down on the tensioner with continuous pressure until the fully extended tensioner bottoms out. see scheme 156 Install oil reservoir cap onto timing chain tensioner. see scheme 155
9. Install timing chain tensioner with oil reservoir cap into engine block. see scheme 148
10. Install timing chain tensioner plug with seal ring. Torque plug to 62 N.m (46 ft. lbs.). WARNING: DO NOT ALLOW FINGERS TO GET TRAPPED BETWEEN THE TIMING CHAIN AND GUIDE
11. Depress the right timing chain guide against the tensioner until it releases. (Scheme 139)
12. Install cylinder head plugs. Torque to 18 N.m (162 in. lbs.). see scheme 149
13. Install cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) ).
14. Install camshaft position sensor. Torque fastener to 10 N.m (85 in. lbs.). Reconnect connector.
15. Install right engine mount bracket «(Refer to ENGINE/ENGINE MOUNTING/ENGINE MOUNT BRACKET - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine).
16. Install the timing chain cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#16l-sohc-engine) ).
17. Connect negative battery cable.

See also:
• (Refer to FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING)
• (Refer to ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING)
• (Refer to ELECTRICAL/STARTING - DIAGNOSIS AND TESTING)
• POWERTRAIN DIAGNOSTIC PROCEDURES
• (Refer to ELECTRICAL/IGNITION CONTROL - SPECIFICATIONS)
• (Refer to EXHAUST SYSTEM - DIAGNOSIS AND TESTING)
• (Refer to EMISSIONS CONTROL/EVAPORATIVE EMISSIONS/PCV VALVE - DIAGNOSIS AND TESTING)
• (Refer to COOLING/ENGINE - STANDARD PROCEDURE)
• HEATING & AIR CONDITIONING
• (Refer to BODY/EXTERIOR/RADIATOR CROSSMEMBER - REMOVAL)
• (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELT - REMOVAL)
• (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)
• (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION)
• (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELT - INSTALLATION)
• (Refer to TRANSMISSION/TRANSAXLE/MANUAL - REMOVAL)
• (Refer to TRANSMISSION/TRANSAXLE/MANUAL - REMOVAL)
• (Refer to TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION)
• (Refer to TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION)
• LUBRICATION & MAINTENANCE
• (Refer to STEERING/PUMP/RESERVOIR - REMOVAL)
• ENGINE MECHANICAL
• ENGINE PERFORMANCE
• CYLINDER COMPRESSION PRESSURE TEST
• CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
• CYLINDER HEAD GASKET
• LASH ADJUSTER NOISE DIAGNOSIS
• ENGINE OIL LEAK INSPECTION
• (Refer to ENGINE - SPECIAL TOOLS)
• INSPECTION FOR REAR SEAL AREA LEAKS
• (Refer to ENGINE/CYLINDER HEAD - CLEANING)
• (Refer to ENGINE - REMOVAL)
• (Refer to ENGINE - INSTALLATION)