2.4l DOHC Engine Chrysler PT Cruiser I

DESCRIPTION

The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft with hydraulic lash adjusters and four valve per cylinder design. The engine is free-wheeling; meaning it has provisions for piston-to-valve clearance. However valve-to-valve interference can occur, if camshafts are rotated independently.

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 located on the rear of the cylinder block. (Scheme 140)

Scheme 140

ENGINE DIAGNOSIS - 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 DIAGNOSIS - PERFORMANCE and ENGINE DIAGNOSIS - MECHANICAL .

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/#24l-dohc-engine__cylinder-compression-pressure-test)
2. «CYLINDER COMBUSTION PRESSURE LEAKAGE TEST»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__cylinder-combustion-pressure-leakage-test)
3. «CYLINDER HEAD GASKET»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__cylinder-head-gasket) Diagnosis
4. «INTAKE MANIFOLD LEAKS»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__intake-manifold-leaks) Diagnosis
5. «HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__hydraulic-lash-adjuster-noise-diagnosis)
6. «ENGINE OIL LEAK INSPECTION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__engine-oil-leak-inspection)

ENGINE DIAGNOSIS - PERFORMANCE

ENGINE DIAGNOSIS - MECHANICAL

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 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.

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.
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. Be sure throttle blade is fully open during the compression check.
6. 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(R). For Special Tool identification, «(Refer to ENGINE - SPECIAL TOOLS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) .
7. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure.
8. Repeat the previous step for all remaining cylinders.
9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder.
10. If one or more cylinders have abnormally low compression pressures, repeat the compression test.
11. 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.

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/#24l-dohc-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(R) 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(R) Engine RTV GEN II, Mopar(R) ATF-RTV, and Mopar(R) Gasket Maker gasket materials, each have different properties and can not be used in place of the other.

MOPAR(R) 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(R) 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(R) 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(R) 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(R) 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(R) Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.

SEALER APPLICATION

Mopar(R) 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(R) 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(R) 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 141)

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 141)
3. Drill motor with 3M Roloc(tm) Bristle Disc (white or yellow). (Scheme 141)

Scheme 141

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 142)

Scheme 142

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(R) Stud and Bearing Mount. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer.

It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately.

MEASURING 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 143

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 143) (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/#24l-dohc-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.

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

1. Perform fuel pressure release procedure, then disconnect and remove fuel line «(Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/fuel-system/#fuel-system).
2. Remove air cleaner housing assembly and clean air hose «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Disconnect both cables from battery.
4. Remove battery and battery tray «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system__removal).
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 throttle and speed control cables from throttle body.
8. Disconnect engine wiring harness at Powertrain Control Module (PCM).
9. Disconnect positive cable from Power Distribution Center (PDC) and ground wire from vehicle body. Remove bolts attaching PDC and set aside. (Scheme 144) 1 - PDC 2 - PDC BRACKET BOLTS 3 - BATTERY TRAY BOLT
10. Disconnect wiring connectors at lower battery tray support.
11. Disconnect ground wire from the vehicle body-to-engine at the right side strut tower.
12. Disconnect brake booster vacuum hose from intake manifold.
13. Disconnect the proportional purge hose from throttle body.
14. Disconnect coolant reserve/recovery hose from coolant outlet connector.
15. Disconnect heater hoses.
16. Remove grill «(Refer to BODY/EXTERIOR/GRILLE - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
17. Remove upper radiator closure and center brace «(Refer to BODY/EXTERIOR/RADIATOR CROSSMEMBER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior). (Scheme 145) 1 - UPPER RADIATOR CLOSURE PANEL 2 - CENTER BRACE
18. Remove upper radiator hose.
19. Remove lower radiator hose.
20. Remove thermostat housing.
21. Disconnect upper A/C line from A/C condenser.
22. Disconnect A/C lines at junction near upper torque strut.
23. Automatic Transmission equipped vehicles: Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with transmission fittings. Plug lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly. Disconnect transmission electrical connectors. Disconnect transmission shift linkage.
24. Manual Transmission equipped vehicles: Using Special Tool 6638A, disconnect clutch hydraulic line. (Scheme 146)and (Scheme 147). Disconnect transmission shift linkage. Disconnect transmission electrical connectors. 1 - SLAVE CYLINDER 2 - HYDRAULIC TUBE 1 - QUICK CONNECT FITTING 2 - TOOL 6638A
25. Turbocharger equipped vehicles: Disconnect power steering hoses from radiator.
26. Disconnect radiator fan electrical connector and remove cooling module assembly (fan, radiator, A/C condenser, transmission oil cooler).
27. Hoist vehicle and remove front wheels.
28. Remove right and left inner splash shields.
29. Remove both axle shafts «(Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/axle-shafts/#differential-driveline__removal).
30. Remove accessory drive belts «(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).
31. Remove generator and support brackets.
32. Turbocharger equipped vehicles: Remove charge air cooler hoses. (Scheme 148) 1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY 2 - CHARGE AIR COOLER 3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
33. Drain engine oil.
34. Disconnect the downstream oxygen sensor connector.
35. Disconnect exhaust system from manifold. (Scheme 149)or (Scheme 150). 1 - GASKET 2 - CATALYTIC CONVERTER 3 - NUT 1 - FLAG NUT 2 - GASKET 3 - NUT 4 - BOLT 5 - CATALYTIC CONVERTER
36. Non-Turbo equipped vehicles: Disconnect power steering pressure hose from steering gear. (Scheme 151)
37. Turbocharger equipped vehicles: Disconnect both power steering hoses from steering gear. (Scheme 152) 1 - STEERING GEAR 2 - FITTING 3 - POWER STEERING PRESSURE HOSE 1 - POWER STEERING GEAR 2 - ROUTING CLIP 3 - PRESSURE HOSE TUBE NUT 4 - RETURN HOSE CLAMP 5 - PRESSURE/RETURN HOSE ASSEMBLY
38. Turbocharger equipped vehicles: Remove upper and lower heat shields, elbow support bracket, turbocharger support bracket, and elbow. (Scheme 153) 1 - UPPER/LOWER HEAT SHIELDS 2 - TURBOCHARGER SUPPORT BRACKET 3 - ELBOW 4 - ELBOW SUPPORT BRACKET
39. Remove structural collar «(Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COLLAR - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
40. Automatic Transmission equipped vehicles: Remove torque converter bolts and mark converter to flex plate orientation for reassembly.
41. Manual Transmission equipped vehicles: Remove drive plate to clutch module bolts.
42. Remove lower engine torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
43. Lower vehicle and remove A/C compressor.
44. Disconnect power steering lines from power steering pump.
45. Remove power steering pump.
46. 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/#24l-dohc-engine).
47. Loosen engine support posts to allow movement for positioning onto engine locating holes and flange on the engine bedplate. Lower vehicle and position cradle until the engine is resting on support posts. (Scheme 156) Tighten mounts to cradle frame. This will keep support posts from moving when removing or installing engine and transmission.
48. Install safety straps around the engine to cradle. (Scheme 156) Tighten straps and lock them into position. WARNING: Safety straps MUST be used.
49. Raise vehicle enough to determine if straps are secure enough to hold cradle assembly to engine.
50. Lower vehicle so weight of the engine and transmission ONLY is on the cradle assembly.
51. Remove the upper engine torque strut.
52. Remove right mount through bolt and left mount attaching bolts. (Scheme 154)and (Scheme 155).
53. Raise 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 154

Scheme 155

Scheme 156

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 154)and (Scheme 155). Tighten bolts to 118 N.m (87 ft. lbs.).
3. Install upper engine torque strut.
4. Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly and cradle.
5. Install power steering pump.
6. Connect power steering lines to power steering pump.
7. Install A/C compressor.
8. Install lower engine torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
9. Automatic Transmission equipped vehicles: Install torque converter bolts.
10. Manual Transmission equipped vehicles: Install drive plate to clutch module bolts.
11. Install structural collar «(Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COLLAR - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
12. Turbocharger equipped vehicles: Install elbow, turbocharger support bracket, elbow support bracket, and upper and lower heat shields. (Scheme 153)
13. Non-Turbo equipped vehicles: Connect power steering pressure hose to steering gear. (Scheme 151)
14. Turbocharger equipped vehicles: Connect both power steering hoses to steering gear. (Scheme 152)
15. Connect exhaust system to manifold or (Scheme 149) (Scheme 150).
16. Connect the downstream oxygen sensor.
17. Turbocharger equipped vehicles: Install charge air cooler hoses. (Scheme 148)
18. Install generator and mounting brackets.
19. Install accessory drive belts «(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).
20. Install axle shafts «(Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/axle-shafts/#differential-driveline__installation).
21. Install right inner splash shield.
22. Install wheels and lower vehicle.
23. Install cooling module assembly (fan, radiator, A/C condenser, transmission oil cooler). Connect radiator fan electrical connector.
24. Turbocharger equipped vehicles: Connect power steering hoses to radiator.
25. Manual Transmission equipped vehicles: Connect clutch hydraulic line. (Scheme 146) Connect transmission shift linkage. Connect transmission electrical connectors. NOTE: It is not necessary to bleed the clutch hydraulic system. The quick-connect fittings close immediately after disconnection; allowing no fluid to escape.
26. Automatic Transmission equipped vehicles: Connect transmission oil cooler lines using service splice kit. Refer to instructions provided with kit. Connect transmission electrical connectors. Connect transmission shift linkage.
27. Connect A/C lines at junction near upper torque strut.
28. Connect upper A/C line to A/C condenser.
29. Install upper and lower radiator hoses.
30. Install upper radiator closure panel and center brace «(Refer to BODY/EXTERIOR/RADIATOR CLOSURE PANEL - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior). see scheme 18 1 - UPPER RADIATOR CLOSURE PANEL 2 - CENTER BRACE
31. Install grille «(Refer to BODY/EXTERIOR/GRILLE - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
32. Connect fuel line and heater hoses.
33. Connect coolant reserve/recovery hose to coolant outlet connector.
34. Connect brake booster vacuum hose to intake manifold.
35. Connect the proportional purge hose to throttle body.
36. Install all ground straps and connect engine wiring harness.
37. Position PDC and install bolts. (Scheme 144) Connect positive battery cable to PDC and ground wire to vehicle body.
38. Connect engine wiring harness at Powertrain Control Module (PCM).
39. Connect throttle and speed control cables.
40. Install battery tray and battery «(Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/charging-system/#battery-system__installation).
41. Connect cables to battery.
42. Install air cleaner housing assembly and connect clean air hose «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
43. Install oil filter. Fill engine crankcase with proper oil to correct level.
44. Fill power steering system.
45. 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).
46. 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) ).
47. Start engine and run until operating temperature is reached.
48. Perform torque strut adjustment procedure «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
49. Adjust transmission linkage, if necessary.

2.4L ENGINE

GENERAL SPECIFICATIONS

CYLINDER BLOCK

PISTONS

PISTON RINGS

CONNECTING ROD

CRANKSHAFT

HYDRAULIC LASH ADJUSTER

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

CAMSHAFT

CYLINDER HEAD

VALVE SEAT

VALVE GUIDE

VALVES

VALVE MARGIN

VALVE STEM TIP

VALVE STEM TO GUIDE CLEARANCE

VALVE SPRINGS

OIL PUMP

OIL PRESSURE

TORQUE

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

1. Unfasten clasps on sides of air cleaner housing cover. Lift cover off air cleaner housing. (Scheme 188)
2. Remove filter element.
3. If necessary, clean the inside of the air cleaner housing.

INSTALLATION

1. Install new filter element.
2. Place cover over air cleaner housing. Snap clasps in place.

REMOVAL

1. Disconnect the throttle body air inlet hose/clean air hose from the air cleaner housing. (Scheme 189) (Scheme 190) and (Scheme 191).
2. Pull air cleaner housing straight up to remove.
3. Remove the inlet duct from the air cleaner housing.

1. Install inlet duct to the air cleaner housing.
2. Make sure the rubber grommets, for the air cleaner housing lower pins, are in place when reinstalling the air cleaner housing. The rubber grommets mount to the PDC bracket. (Scheme 189)or (Scheme 190).
3. Push air cleaner housing down while aligning pins into the grommets.
4. Connect the throttle body air inlet hose/clean air hose to the air cleaner housing. (Scheme 189) (Scheme 190) or (Scheme 191).

Scheme 189

Scheme 190

Scheme 191

The cross flow designed, aluminum cylinder head contains dual over-head camshafts with four valves per cylinder. (Scheme 192) The valves are arranged in two in-line banks. The intake valves face toward the front of the vehicle. The exhaust valves face the dash panel. The cylinder head incorporates powdered metal valve guides and seats. The cylinder head is sealed to the block using a multi-layer steel head gasket and retaining bolts.

Integral oil galleries provide lubrication passages to the hydraulic lash adjusters, camshafts, and valve mechanisms.

Scheme 192

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.

Scheme 193

Scheme 194

Scheme 195

1. Perform fuel system pressure release procedure before attempting any repairs «(Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/fuel-system/#fuel-system).
2. Remove clean air hose and air cleaner housing «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Disconnect negative cable from battery.
4. 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).
5. Remove upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
6. Remove fastener attaching dipstick tube to lower intake manifold. (Scheme 193)or (Scheme 194).
7. Turbocharger equipped vehicles: Remove lower intake manifold support bracket. (Scheme 194) 1 - DIPSTICK TUBE 2 - SCREW 1 - UPPER INTAKE MANIFOLD 2 - LOWER INTAKE MANIFOLD 3 - SUPPORT BRACKET 4 - DIPSTICK TUBE SCREW
8. Disconnect the fuel supply line quick-connect at the fuel rail assembly «(Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/fuel-system/#fuel-system).
9. Remove heater tube support bracket from cylinder head.
10. Remove upper radiator hose. Disconnect heater hoses from thermostat housing.
11. Disconnect engine coolant temperature sensor connector.
12. Remove accessory drive belts «(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).
13. Disconnect exhaust pipe from manifold.
14. Turbocharger equipped vehicles:. see scheme 57Remove turbocharger heat shields Remove elbow support bracket Remove turbocharger support bracket Remove elbow 1 - UPPER/LOWER HEAT SHIELDS 2 - TURBOCHARGER SUPPORT BRACKET 3 - ELBOW 4 - ELBOW SUPPORT BRACKET
15. Turbocharger equipped vehicles: «(Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/LINES AND HOSES - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/blowers-superchargers-turbochargers/#exhaust-system-turbocharger__removal-lines-and-hoses). (Scheme 195) Remove oil return tube Remove oil supply line Remove coolant supply line Remove coolant return line 1 - OIL SUPPLY LINE 2 - COOLANT RETURN LINE 3 - COOLANT SUPPLY LINE 4 - OIL RETURN TUBE
16. Disconnect ignition coil wiring connector. Remove ignition coil and plug wires from engine.
17. Disconnect camshaft position sensor wiring connector.
18. Remove timing belt and camshaft sprockets «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
19. Remove timing belt idler pulley and rear timing belt cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) ).
20. Non-Turbo equipped vehicles: Remove fasteners securing power steering pump fluid reservoir/bracket to cylinder head.
21. Remove cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
22. Remove camshafts «(Refer to ENGINE/CYLINDER HEAD/CAMSHAFT(S) - REMOVAL»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) ).
23. Remove rocker arms.
24. Remove cylinder head bolts in the reverse sequence of tightening. (Scheme 201)
25. Remove cylinder head from engine block.
26. Inspect and clean cylinder head and block sealing surfaces. Refer to «CLEANING»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__cleaning) and «INSPECTION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__inspection) for procedures.

Note. Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

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 196

1. Cylinder head must be flat within 0.1 mm (0.004 in.). (Scheme 196)
2. Inspect camshaft bearing journals for scoring. 1 - FEELER GAUGE 2 - STRAIGHT EDGE
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 197) «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine). Replace guides if they are not within specification.
5. Check valve guide height. (Scheme 198)

Scheme 197

Scheme 198

INSTALLATION - CYLINDER HEAD

Note. The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced. (Scheme 199)

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 should be replaced.

Scheme 199

Scheme 200

Note. Head gaskets for Non-Turbo and Turbo applications are NOT interchangeable.

Scheme 201

1. Position the new cylinder head gasket on engine block with the part number facing up. (Scheme 200) Ensure gasket is seated over the locating dowels in block.
2. Position cylinder head onto engine block.
3. Before installing the bolts, the threads should be lightly coated with engine oil.
4. For Non -Turbo equipped engines tighten the cylinder head bolts in the sequence (Scheme 201) Using the 4 step torque-turn method, tighten according to the following values: First: All to 34 N.m (25 ft. lbs.) Second: All to 68 N.m (50 ft. lbs.) Third: All to 68 N.m (50 ft. lbs.) CAUTION: Do not use a torque wrench for the Fourth step. Fourth: Turn all bolts an additional 1/4 Turn
5. For Turbo equipped engines tighten the cylinder head bolts in the sequence (Scheme 201) Using the 4 step torque-turn method, tighten according to the following values: First: All to 34 N.m (25 ft. lbs.) Second: All to 82 N.m (60 ft. lbs.) Third: All to 82 N.m (60 ft. lbs.) CAUTION: Do not use a torque wrench for the Fourth step. Fourth: Turn all bolts an additional 1/4 Turn
6. Install rocker arms and camshafts «(Refer to ENGINE/CYLINDER HEAD/CAMSHAFT(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) ).
7. Install cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
8. Install rear timing belt cover and timing belt idler pulley «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) ).
9. Install camshaft sprockets and timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
10. Connect cam sensor wiring connector.
11. Install ignition coil and plug wires. Connect ignition coil wiring connector.
12. Non-Turbo equipped vehicles: Install power steering pump reservoir/bracket to cylinder head.
13. Turbocharger equipped vehicles: «(Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/LINES AND HOSES - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/blowers-superchargers-turbochargers/#exhaust-system-turbocharger__installation-lines-and-hoses). (Scheme 195) Install coolant return line Install coolant supply line Install oil supply line Install oil return tube
14. Turbocharger equipped vehicles:. see scheme 57Install elbow Install turbocharger support bracket Install elbow support bracket Install turbocharger heat shields
15. Install exhaust pipe to manifold. Tighten fasteners to 28 N.m (20 ft. lbs.).
16. Install accessory drive belts «(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).
17. Connect engine coolant temperature sensor connector.
18. Connect upper radiator hose. Connect heater hoses to thermostat housing.
19. Install heater tube support bracket to cylinder head.
20. Turbocharger equipped vehicles: Install lower intake manifold support bracket. (Scheme 194)
21. Install fastener attaching dipstick tube to lower intake manifold. (Scheme 193)or (Scheme 194).
22. Connect fuel supply line quick-connect at the fuel rail assembly «(Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/fuel-system/#fuel-system).
23. Install upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
24. 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).
25. Connect negative cable to battery.
26. Install clean air hose and air cleaner housing «(Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

1. Remove timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Hold each camshaft sprocket with Special Tool 6847 while removing center bolt. (Scheme 202)
3. Remove camshaft sprockets.
4. Remove rear timing belt cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) ).
5. Remove camshaft seal using Special Tool C-4679A. (Scheme 203)

Scheme 202

Scheme 203

Scheme 204

1. Shaft seal surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary.
2. Install camshaft seals into cylinder head using Special Tool MD-998306 until flush with head. (Scheme 204) 1 - SPECIAL TOOL MD-998306
3. Install timing belt rear cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) ).
4. Install camshaft sprockets. Hold each sprocket with Special Tool 6847 and tighten center bolt to 115 N.m (85 ft. lbs.). (Scheme 202)
5. Install timing belt and front covers «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) and «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) ).

Both camshafts have six bearing journal surfaces and two cam lobes per cylinder. see scheme 68 Flanges at the rear journals control camshaft end play. Provision for a cam position sensor is located on the intake camshaft on the rear of the cylinder head. A hydrodynamic oil seal is used for oil control at the front of the camshaft.

OPERATION

The camshaft is driven by the crankshaft via drive sprockets and belt. The camshaft has precisely machined lobes to provide accurate valve timing and duration.

MEASURING CAMSHAFT END PLAY

1. Oil camshaft journals and install camshaft WITHOUT rocker arms. Install rear cam caps and tighten screws to specified torque.
2. Using a suitable tool, move camshaft as far rearward as it will go.
3. Zero dial indicator. (Scheme 205)
4. Move camshaft as far forward as it will go.
5. Record reading on dial indicator. For end play specification, «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
6. If end play is excessive, check cylinder head and camshaft for wear; replace as necessary.

Scheme 205

1. Remove cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Remove camshaft position sensor and camshaft target magnet «(Refer to ELECTRICAL/IGNITION CONTROL/CAMSHAFT POSITION SENSOR - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/ignition-system/#ignition-control).
3. Remove timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
4. Remove camshaft sprockets and timing belt rear cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) ).
5. Bearing caps are identified for location. Remove the outside bearing caps first. (Scheme 206)
6. Loosen the camshaft bearing cap attaching fasteners in sequence shown one camshaft at a time. (Scheme 207) CAUTION: Camshafts are not interchangeable. The intake cam number 6 thrust bearing face spacing is wider.
7. Identify the camshafts before removing from the head. The camshafts are not interchangeable.
8. Remove camshafts from cylinder head.

Note. If removing rocker arms, identify for reinstallation in the original position.

Scheme 206

Scheme 207

Clean camshaft with a suitable solvent.

INSPECTION

1. Inspect camshaft bearing journals for damage and binding. (Scheme 208) 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. NOTE: If camshaft is replaced due to lobe wear or damage, always replace the rocker arms.
3. 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 208) limit is 0.254 mm (0.010 in.).

Scheme 208

Scheme 209

Scheme 210

1. Lubricate all camshaft bearing journals, rocker arms and camshaft lobes.
2. Install all rocker arms in original positions, if reused.
3. Position camshafts on cylinder head bearing journals. Install right and left camshaft bearing caps No. 2 - 5 and right No. 6. Tighten M6 fasteners to 12 N.m (105 in. lbs.) in sequence (Scheme 209)
4. Apply Mopar(R) Gasket Maker to No. 1 and No. 6 bearing caps. (Scheme 210) Install bearing caps and tighten M8 fasteners to 28 N.m (250 in. lbs.). 1 - 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET MAKER NOTE: Bearing end caps must be installed before seals can be installed.
5. Install camshaft oil seals «(Refer to ENGINE/CYLINDER HEAD/CAMSHAFT OIL SEAL(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) ).
6. Install camshaft target magnet and camshaft position sensor.
7. Install cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
8. Install timing belt rear cover and camshaft sprockets «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) ).
9. Install timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

1. Remove upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Remove ignition coil and spark plug wires.
3. Disconnect PCV and make-up air hoses from cylinder head cover. (Scheme 211)
4. Remove cylinder head cover bolts. CAUTION: When removing cylinder head cover bolts, be careful not to interchange the two (2) center bolts with the seven (7) perimeter bolts. The two (2) center bolts contain an aluminum washer between the bolt head and torque limiter for sealing purposes.
5. Remove cylinder head cover from cylinder head.

Scheme 211

Note. Replace spark plug well seals and bolt seals when installing a new cylinder head cover gasket.

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

1. Install new cylinder head cover gaskets and spark plug well seals. (Scheme 212)and (Scheme 213).
2. Replace cylinder head cover bolt seals. (Scheme 214) 1 - SPARK PLUG WELL SEALS 2 - GASKET CAUTION: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping.
3. Apply Mopar(R) Engine RTV GEN II at the camshaft cap corners and at the top edges of the 1/2 round seal. (Scheme 215) 1 - SEALER LOCATION CAUTION: When installing cylinder head cover bolts, be careful not to interchange the two (2) center bolts with the seven (7) perimeter bolts. The two (2) center bolts contain an aluminum washer between the bolt head and torque limiter for sealing purposes.
4. Install cylinder head cover assembly to cylinder head. Install all bolts, ensuring the two (2) bolts containing the sealing washer are located in the center locations of cover. Tighten bolts in sequence (Scheme 216) Using a 3 step torque method as follows: Tighten all bolts to 4.5 N.m (40 in. lbs.). Tighten all bolts to 9.0 N.m (80 in. lbs.). Tighten all bolts to 12 N.m (105 in. lbs.).
5. Install ignition coil and spark plug wires. Tighten fasteners to 12 N.m (105 in. lbs.).
6. If the PCV valve was removed, apply Mopar(R) Thread Sealant with Teflon to threads and install valve to cylinder head cover. Tighten PCV valve to 8 N.m (70 in. lbs.).
7. Connect PCV and make-up air hoses to cylinder head cover. (Scheme 211)
8. Install upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

HYDRAULIC 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 cylinder 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 lash adjusters, and replace as necessary.

Note. This procedure is for in-vehicle service with camshafts installed.

1. Remove cylinder head cover. «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)
2. Remove rocker arm. «(Refer to ENGINE/CYLINDER HEAD/ROCKER ARMS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)
3. Remove hydraulic lash adjuster. (Scheme 217)
4. Repeat removal procedure for each hydraulic lash adjuster.
5. If reusing, mark each hydraulic lash adjuster for reassembly in original position. Lash adjusters are serviced as an assembly.

Scheme 217

1. Install hydraulic lash adjuster. (Scheme 217) Ensure the lash adjusters are at least partially full of engine oil. This is indicated by little or no plunger travel when the lifter is depressed.
2. Install rocker arm. «(Refer to ENGINE/CYLINDER HEAD/ROCKER ARMS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)
3. Repeat installation procedure for each hydraulic lash adjuster.
4. Install cylinder head cover. «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)

The valves are made of heat resistant steel. They have chrome plated stems to prevent scuffing. Viton rubber valve stem seals are integral with the spring seats. The valves have three-bead lock keepers to retain springs and to promote valve rotation.

The four valves per cylinder (two intake and two exhaust) are opened by using roller rocker arms which pivot on hydraulic lash adjusters.

1. Clean all valves thoroughly and discard burned, warped and cracked valves.

Note. This procedure is for in-vehicle service with camshafts installed.

1. Remove cylinder head cover. «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)
2. Remove spark plugs.
3. Rotate engine until the camshaft lobe, on the follower being removed, is positioned on its base circle (heel). Also, the piston should be a minimum of 6.3 mm (0.25 in) below TDC position. CAUTION: If cam follower assemblies are to be reused, always mark position for reassembly in their original positions.
4. Using Special Tools 8215A and 8436 slowly depress valve assembly until rocker arm can be removed. (Scheme 218)
5. Repeat removal procedure for each rocker arm.

Scheme 218

Inspect the rocker arm for wear or damage. (Scheme 219) Replace as necessary.

Scheme 219

1. Lubricate rocker arm with clean engine oil.
2. Using Special Tools 8215A and 8436 slowly depress valve assembly until rocker arm can be installed on the hydraulic lifter and valve stem. (Scheme 218)
3. Repeat installation procedure for each rocker arm.
4. Install spark plugs.
5. Install cylinder head cover. «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)

CYLINDER HEAD ON

1. Remove cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Remove camshafts «(Refer to ENGINE/CYLINDER HEAD/CAMSHAFT(S) - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Rotate crankshaft until piston is at TDC on compression.
4. With air hose attached to adapter tool installed in spark plug hole, apply 90-120 psi air pressure.
5. Using Special Tool MD-998772-A with adapter 6779, compress valve springs and remove valve locks. (Scheme 220)
6. Remove valve spring(s).
7. Remove valve stem seal(s) by a using valve stem seal tool. (Scheme 222)

Scheme 220

CYLINDER HEAD OFF

1. With cylinder head removed from cylinder block, compress valve springs using a universal valve spring compressor.
2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs.
3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves, locks and retainers to insure installation in original location.
4. Inspect the valves. «(Refer to ENGINE/CYLINDER HEAD/VALVE SPRINGS - INSPECTION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)

1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct tension. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: Valve Closed Nominal Tension-75 lbs. @ 38.0 mm (1.50 in.) Valve Open Nominal Tension-134 lbs. @ 29.75 mm (1.17 in.)
2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring.

1. Install valve seal/valve spring seat assembly. (Scheme 221) Push the assembly down to seat it onto the valve guide.
2. Install valve spring and retainer, use Special Tool MD-998772-A with adapter 6779 to compress valve springs only enough to install locks. (Scheme 220) Correct alignment of tool is necessary to avoid nicking valve stems.
3. Remove air hose and install spark plugs.
4. Install camshafts «(Refer to ENGINE/CYLINDER HEAD/CAMSHAFT(S) - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
5. Install cylinder head cover «(Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

Scheme 221

Scheme 222

1. Coat valve stems with clean engine oil and insert in cylinder head.
2. Install new valve stem seals on all valves using a valve stem seal tool. (Scheme 222) The valve stem seals should be pushed firmly and squarely over valve guide. CAUTION: When oversize valves are used, the corresponding oversize valve seal must also be used. Excessive guide wear may result if oversize seals are not used with oversize valves. 1 - VALVE SEAL TOOL 2 - VALVE STEM
3. Install valve springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Ensure both locks are in the correct location after removing tool.
4. Check the valve spring installed height B after refacing the valve and seat. (Scheme 223) Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 in.), install a 0.762 mm (0.030 in.) spacer under the valve spring seat to bring spring height back within specification.

Scheme 223

The cast iron cylinder block is a two-piece assembly, consisting of the cylinder block and bed plate. (Scheme 224) The bed plate incorporates the main bearing caps and bolts to the cylinder block. This design offers a much stronger lower end and increased cylinder block rigidity. The rear oil seal retainer is integral with the block. The bed plate and block are serviced as an assembly.

Scheme 224

Scheme 225

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 225) 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/#24l-dohc-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 226)(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 226

Measure the cylinder bore at three levels in directions A and B. (Scheme 226) 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).

MEASURING CRANKSHAFT END PLAY

1. Mount a dial indicator to front of engine with the locating probe on nose of crankshaft. (Scheme 227)
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 and read the dial indicator. «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) for end play specification.

Scheme 227

REMOVAL - CRANKSHAFT

Note. Crankshaft can not be removed when engine is in vehicle.

Scheme 228

Scheme 229

1. Remove engine assembly from vehicle «(Refer to ENGINE - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__removal).
2. Separate transaxle from engine.
3. Remove drive plate/flex plate.
4. Remove crankshaft rear oil seal «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
5. Mount engine on a suitable repair stand.
6. Drain engine oil and remove oil filter.
7. Remove crankshaft vibration damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
8. Remove engine mount support bracket.
9. Remove front timing belt covers «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
10. Remove the timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
11. Remove the rear timing belt cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
12. Remove the oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
13. Remove oil pump pick-up tube.
14. Remove the crankshaft sprocket and oil pump «(Refer to ENGINE/LUBRICATION/OIL PUMP - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
15. Remove balance shafts and housing assembly «(Refer to ENGINE/VALVE TIMING/BALANCE SHAFT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
16. Remove crankshaft position sensor. NOTE: If piston/connecting rod replacement is necessary, remove cylinder head «(Refer to ENGINE/CYLINDER HEAD - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
17. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. (Scheme 228) CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
18. 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.
19. Remove all bed plate bolts from the engine block. (Scheme 229)
20. Using a mallet gently tap the bedplate 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 to bed plate alignment and thrust bearing.
21. Bed plate should be removed evenly from the cylinder block dowel pins to prevent damage to the dowel pins and thrust bearing. CAUTION: Use extreme care when handling crankshaft. Tone wheel damage can occur if crankshaft is mis-handled.
22. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft.
23. Remove the target ring mounting screws and discard.
24. Remove the target ring from the crankshaft.

The crankshaft journals should be checked for excessive wear, taper and scoring. (Scheme 230) 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 230

CRANKSHAFT MAIN BEARING LOCATION

The crankshaft is supported in five main bearings. All upper bearing shells in the crankcase have oil grooves and holes. All lower bearing shells except for the thrust bearing half have oil grooves and holes. (Scheme 231) Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal.

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

1. Install the main bearing upper shells with the lubrication groove and oil hole in the engine block. (Scheme 232) 1 - LUBRICATION GROOVES 2 - OIL HOLES
2. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. 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. NOTE: If the crankshaft is sent out for machine work, it must be balanced as an assembly with the target ring installed.
3. Clean crankshaft and target ring with MOPAR(R) Brake Parts cleaner and dry with compressed air to ensure that the crankshaft mating surface and target ring mounting holes are free from oil and lock patch debris. NOTE: Always use NEW mounting screws whether installing original or new target ring.
4. Install NEW mounting screws finger tight starting with the #1 location. Make sure engagement occurs with the shoulder of the screws and mounting hole before starting all other screws.
5. Torque all mounting screws with T30 torx bit to 13 Nm (110 in-lbs) following the torque sequence. (Scheme 233)1 - TARGET RING
6. Oil the bearings and journals. Install crankshaft in engine block. CAUTION: Use only the specified anaerobic sealer on the bed plate or damage may occur to the engine.
7. Apply a 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of Mopar(R) Bed Plate Sealant to bed plate (Scheme 234)
8. 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 into engine block.
9. Before installing the bolts the threads should be oiled with clean engine oil, wipe off any excess oil.
10. Install main bearing cap/bed plate to engine block bolts 11, 17, and 20 finger tight. Tighten these bolts down together until the bed plate contacts the cylinder block. (Scheme 235)
11. To ensure correct thrust bearing alignment, perform the following steps: Step 1: Rotate crankshaft until number 4 piston is at TDC. Step 2: Move crankshaft rearward to limits of travel. Step 3: Then, move crankshaft forward to limits of travel. Step 4: Wedge an appropriate tool between the rear of the cylinder block (NOT BED PLATE) and the rear crankshaft counterweight. This will hold the crankshaft in it's furthest forward position. Step 5: Install and tighten bolts (1-10) in sequence (Scheme 235)to 41 N.m (30 ft. lbs.). Step 6: Remove wedge tool used to hold crankshaft.
12. Tighten bolts (1-10) again to 41 N.m (30 ft. lbs.) in sequence (Scheme 235)
13. Install main bearing bed plate to engine block bolts (11-20), and torque each bolt to 28 N.m (250 in. lbs.) in sequence (Scheme 235)
14. Tighten bolts (1-10) to 75 N.m (55 ft. lbs.) in sequence (Scheme 235)
15. Tighten bolts (11-20) again to 28 N.m (250 in. lbs.) in sequence (Scheme 235)
16. 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.).
17. Check crankshaft end play «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
18. Install connecting rod bearings and caps. Do Not Reuse Connecting Rod Bolts. Torque connecting rod bolts to 27 N.m (20 ft. lbs.) plus 1/4 turn.
19. Install balance shafts and housing assembly «(Refer to ENGINE/VALVE TIMING/BALANCE SHAFT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
20. Install the oil pump «(Refer to ENGINE/LUBRICATION/OIL PUMP - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
21. Install oil pump pick-up tube. Torque fastener to 23 N.m (200 in. lbs.).
22. Install the oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
23. Install crankshaft position sensor.
24. Install cylinder head if it was removed «(Refer to ENGINE/CYLINDER HEAD - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
25. Install the timing belt rear cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
26. Install front crankshaft oil seal and crankshaft sprocket «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
27. Install the timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
28. Install the timing belt front covers «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
29. Install engine mount support bracket.
30. Install crankshaft vibration damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
31. Install NEW oil filter.
32. 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.
33. Install crankshaft rear oil seal «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
34. Install drive plate/flex plate. Apply Mopar(R) Lock & Seal Adhesive to bolt threads and tighten to 95 N.m (70 ft. lbs.).
35. Attach transaxle to engine. Tighten attaching bolts to 101 N.m (75 ft. lbs.).
36. Install the engine assembly «(Refer to ENGINE - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__installation).

Scheme 236

1. Remove the crankshaft vibration damper. «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)
2. Remove timing belt. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)
3. Remove crankshaft sprocket using Special Tool 6793 and insert C-4685-C2. (Scheme 236) CAUTION: Do not nick shaft seal surface or seal bore. 1 - SPECIAL TOOL 6793 2 - SPECIAL TOOL C-4685-C2 3 - CRANKSHAFT SPROCKET
4. Using Tool 6771 to remove front crankshaft oil seal. (Scheme 237) Be careful not to damage the seal surface of cover.

Scheme 237

Scheme 238

Scheme 239

1. Install new seal by using Special Tool 6780. (Scheme 238)
2. Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover. 1 - PROTECTOR 2 - SEAL 3 - SPECIAL TOOL 6780
3. Install crankshaft sprocket using Special Tool 6792. (Scheme 239) 1 - SPECIAL TOOL 6792 2 - TIGHTEN NUT TO INSTALL
4. Install timing belt. «(Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)
5. Install crankshaft vibration damper. «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)

1. Remove transaxle. Refer to «OVERHAUL - G288»(/chrysler/pt-cruiser/i-2000-2010/remont/manual-trans/#g288-manual-transmission-overhaul) or «OVERHAUL - T350»(/chrysler/pt-cruiser/i-2000-2010/remont/manual-trans/#t350-manual-transmission-overhaul).
2. Remove flex plate.
3. Insert a 3/16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal. Angle the screwdriver. (Scheme 240)through the dust lip against metal case of the seal. Pry out seal.

Scheme 240

Note. When installing seal, no lube on seal is needed.

Scheme 241

Scheme 242

Scheme 243

1. Place Special Tool 6926-1 Seal Guide on crankshaft. (Scheme 241)
2. Position seal over guide tool. (Scheme 241) Guide 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, this may cause an oil leak.
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 242)and (Scheme 243). 1 - SPECIAL TOOL 6926-1 PILOT 2 - SEAL 1 - SPECIAL TOOL 6926-1 PILOT 2 - SEAL 3 - SPECIAL TOOL 6926-2 INSTALLER 4 - SPECIAL TOOL C-4171 1 - SPECIAL TOOL 6926-2 INSTALLER
4. Install flex plate. Apply Mopar(R) Lock & Seal Adhesive to bolt threads and tighten bolts to 95 N.m (70 ft. lbs.).
5. Install transaxle. Refer to «OVERHAUL - G288»(/chrysler/pt-cruiser/i-2000-2010/remont/manual-trans/#g288-manual-transmission-overhaul) or «OVERHAUL - T350»(/chrysler/pt-cruiser/i-2000-2010/remont/manual-trans/#t350-manual-transmission-overhaul) for procedure.

Non-Turbo

The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged powdered metal connecting rods. The pistons pin is offset 1 mm (0.0394 in.) towards the thrust side of the piston. 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.

Turbo

The pistons are made of a cast aluminum alloy. The pistons have full floating pins attached to forged steel connecting rods. The pistons pin is offset 1 mm (0.0394 in.) towards the thrust side of the piston. 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 connecting rod has an oil squirt hole to provide extra cylinder wall lubrication. The pistons and connecting rods are serviced as an assembly.

PISTON TO CYLINDER BORE FITTING

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

Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin.

Non-Turbo

1. Measurement should be taken approximately 14 mm (0.551 in.) from the bottom of the skirt (Scheme 244)

Turbo

1. Measurement should be taken approximately 22 mm (0.866 in.) from the bottom of the skirt (Scheme 245)

Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location B) to the engine crankshaft center line see scheme 110 (Refer to ENGINE - SPECIFICATIONS). Correct piston to bore clearance must be established in order to assure quiet and economical operation.

Scheme 244

Scheme 245

Scheme 246

1. Remove cylinder head «(Refer to ENGINE/CYLINDER HEAD - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Remove oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Remove Balance Shaft Carrier Assembly. Refer to «BALANCE SHAFT CARRIER»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__balance-shaft-carrier)
4. 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. 1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
5. Pistons have a directional stamping in the front half of the piston facing towards the front of engine. (Scheme 246)
6. Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore.
7. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. see scheme 112 CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur.
8. Remove connecting rod bolts and cap. Care should be taken not to damage the fracture rod and cap surfaces. NOTE: Do not reuse connecting rod bolts. CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage many occur.
9. To protect crankshaft journal and fractured rod surfaces, install Special Tool 8189, connecting rod guides onto connecting rod. (Scheme 247) Carefully push each piston and rod assembly out of cylinder bore. NOTE: On Turbocharger equipped engines, be careful not to damage the oil jet assembly when removing piston/connecting rod. (Scheme 248)
10. Remove Special Tool 8189, connecting rod guides and re-install bearing cap on the mating rod. NOTE: Piston and rods are serviced as an assembly.
11. Repeat procedure for each piston and connecting rod assembly.
12. Remove piston rings «(Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

1. Install piston rings on piston «(Refer to ENGINE/ENGINE BLOCK/PISTON RINGS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. (Scheme 249)
3. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located (Scheme 249) As viewed from top.
4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. (Scheme 250) Be sure position of rings does not change during this operation. 1 - GAP OF LOWER SIDE RAIL 2 - NO. 1 RING GAP 3 - GAP OF UPPER SIDE RAIL 4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
5. The directional stamp on the piston should face toward the front of the engine. (Scheme 246)
6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil.
7. Install connecting rod upper bearing half into connecting rod. Install Special Tool 8189, connecting rod guides onto connecting rod. (Scheme 247)
8. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.
9. Remove Special Tool 8189, connecting rod guides. NOTE: The connecting rod cap bolts should not be reused.
10. Before installing the NEW bolts, the threads should be coated with clean engine oil.
11. Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap.
12. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly.
13. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values: CAUTION: Do not use a torque wrench for the second step. Tighten the bolts to 27 N.m (20 ft. lbs.). Tighten the connecting rod bolts an additional 1/4 TURN.
14. Using a feeler gauge, check connecting rod side clearance. (Scheme 251) «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) for connecting rod side clearance.
15. Install Balance Shaft Carrier Assembly. Refer to «BALANCE SHAFT CARRIER»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__balance-shaft-carrier).
16. Install oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
17. Install cylinder head «(Refer to ENGINE/CYLINDER HEAD - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

CONNECTING ROD - FITTING

1. For measuring connecting rod bearing clearance procedure and use of Plastigage «(Refer to ENGINE - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine). For bearing clearance «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine). NOTE: The rod bearing bolts should not be reused.
2. Before installing the NEW bolts the threads should be oiled with clean engine oil.
3. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly.
4. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values: CAUTION: Do not use a torque wrench for the second step. Tighten the bolts to 27 N.m (20 ft. lbs.). Tighten the connecting rod bolts an additional 1/4 TURN.
5. Using a feeler gauge, check connecting rod side clearance. see scheme 118 Refer to clearance specifications «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

Scheme 252

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 positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge. (Scheme 252) «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine). 1 - FEELER GAUGE
2. Check piston ring to groove side clearance. (Scheme 253) «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

Scheme 253

Scheme 254

1. Using a suitable ring expander, remove upper and intermediate piston rings. (Scheme 254)
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.

Note. The identification mark on face of upper and intermediate piston rings must point toward top of piston.

Install rings with manufacturers identification mark facing up, to the top of the piston. (Scheme 255)

Scheme 255

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 256

1. Install oil ring expander. (Scheme 255)
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 256) 1 - SIDE RAIL END
3. Install No. 2 piston ring and then No. 1 piston ring. (Scheme 255)
4. Position piston ring end gaps (Scheme 257)
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 257

STRUCTURAL COLLAR-AUTOMATIC TRANSAXLE EQUIPPED

1. Raise vehicle on hoist.
2. Remove bolts attaching bending strut to engine and transaxle. (Scheme 258)
3. Remove bolts attaching collar and strut to engine, oil pan, and transaxle. (Scheme 258) Remove strut and collar.

Scheme 258

STRUCTURAL COLLAR-MANUAL TRANSAXLE EQUIPPED

1. Raise vehicle on hoist.
2. Remove bolts attaching bending strut to engine and transaxle. (Scheme 259) Remove strut.
3. Remove bolts attaching collar and clutch slave cylinder to transaxle. (Scheme 259)
4. Remove remaining bolts attaching collar to oil pan and transaxle. (Scheme 259) Remove collar.

Scheme 259

Scheme 260

1. Perform the following steps for installing structural collar and bending strut. (Scheme 258): 1 - POWER STEERING HOSE 2 - BOLT Step 1: Place collar into position between transaxle and oil pan. Install collar to transaxle bolt (1), hand start only. Step 2: Position power steering hose support bracket and install collar to oil pan bolt (4), hand tight only. (Scheme 260) Step 3: Position bending strut in place and hand start only bolt (3) into the upper transaxle hole. Step 4: Install bolt (2), through strut and collar, hand start only. Step 5: Install bolt (6), strut to cylinder block, hand tight only. Step 6: Position power steering hose support bracket and install the remaining collar to oil pan bolt (5), hand tight only.. (Scheme 260) Step 7: Final torque collar to transaxle bolts (1-3), to 101 N.m (75 ft. lbs.) Step 8: Install bolts (7) and (8), through strut and into cylinder block. Step 9: Final torque bolts (4-8) to 61 N.m (45 ft. lbs.).
2. Lower vehicle.

1. Perform the following steps for installing structural collar and bending strut. (Scheme 259): Step 1: Place collar into position between transaxle and oil pan. Install collar to transaxle bolt (1), hand start only. Step 2: Position power steering hose support bracket and install collar to oil pan bolt (2), hand tight only. (Scheme 259) Step 3: Position clutch slave cylinder into mounting position and install bolts (3) and (4) hand tight only. Step 4: Position power steering hose support bracket and install the remaining collar to oil pan bolt (5) hand tight only. Step 5: Final torque all bolts in sequence (Scheme 259)to the following torque values: Bolt (1) to 101 N.m (75 ft. lbs.) Bolts (2) and (5) to 61 N.m (45 ft. lbs.) Bolts (3) and (4) to 28 N.m (20 ft. lbs.)
2. Lower vehicle.

1. Remove accessory drive belts «(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).
2. Remove crankshaft damper bolt.
3. Remove damper by using Special Tool 1026 and Insert 6827A. (Scheme 261)

Scheme 261

1. Install crankshaft damper using Special Tool 6792 (M12 1.75 x 150 mm bolt, washer, thrust bearing and nut). NOTE: Lubricate the threads of the M12 1.75 x 150 mm bolt using Mopar(R) Nickel Anti-seize Compound or equivalent, before beginning to press the damper on.
2. Apply Mopar(R) Lock & Seal Adhesive (Medium Strength Threadlocker) to crankshaft damper bolt and tighten to 136 N.m (100 ft. lbs.). (Scheme 262)
3. Install accessory drive belts «(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).

Scheme 262

The engine mounting system ( (Scheme 263)and (Scheme 265) ) 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 strut connects to the suspension strut tower and the lower to the suspension crossmember.

The four-point engine mounting system minimizes the transmission of structure-borne engine noise to the passenger compartment. The load-carrying right and left mounts dampen and isolate vertical motion and vibration. The two struts absorbs torque reaction forces and torsional vibrations.

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 130
4. Support transaxle with a suitable jack.
5. Remove mount to transaxle bolts. (Scheme 263)
6. Remove left mount bracket to body frame rail fasteners. (Scheme 263)
7. Remove mount.

Scheme 263

1. Install engine mount bracket to body frame rail and tighten fasteners to 28 N.m (250 in. lbs.). (Scheme 263)
2. Position engine/transaxle for installation of mount to transaxle bolts. Install and tighten bolts to 68 N.m (50 ft. lbs.). (Scheme 263)
3. Remove jack from under transaxle.
4. Install bolts attaching the power distribution center (PDC) bracket to left mount and battery tray. see scheme 130
5. Connect negative cable to battery.
6. Install air cleaner assembly.

1. Remove the engine assembly for the required clearance to access the engine mount «(Refer to ENGINE - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__removal). 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 264)
4. Remove mount.

Scheme 264

1. Position mount into the original position on body frame rail. (Scheme 264) 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 the mount position was not previously marked, or the frame rail was replaced: Insert 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 264)
4. Install the engine assembly «(Refer to ENGINE - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine__installation).

UPPER

1. Remove bolts attaching upper torque strut to shock tower bracket and engine mount bracket. (Scheme 265)
2. Remove timing belt front upper cover (if A/C equipped).
3. Remove the upper torque strut.

Scheme 265

Scheme 266

Scheme 267

1. Raise vehicle on hoist.
2. Remove accessory drive belt splash shield. (Scheme 266)
3. Remove pencil strut. (Scheme 267) 1 - RIGHT MOUNT BOLT ACCESS PLUG 2 - FASCIA 3 - SPLASH SHIELD 4 - CRANKSHAFT BOLT ACCESS PLUG 1 - NUT 2 - PENCIL STRUT 3 - NUT 4 - FLAT WASHER 5 - LOWER TORQUE STRUT
4. Remove bolts attaching lower torque strut to crossmember and strut bracket. (Scheme 265)
5. Remove lower torque strut.

1. Position the upper torque strut into mounting location. (Scheme 265)
2. Move torque strut aside (towards right fender) and install timing belt front upper cover (if A/C equipped).
3. Install the torque strut mounting bolts and perform the torque strut adjustment procedure «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

INSTALLATION - LOWER

1. Position lower torque strut into mounting locations.
2. Install mounting bolts and perform torque strut adjustment procedure «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Install pencil strut and tighten nuts to 58 N.m (43 ft. lbs.). (Scheme 267)
4. Install accessory belt splash shield and lower vehicle. (Scheme 266)

ENGINE TORQUE STRUT 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 268

Scheme 269

1. Remove accessory drive belt splash shield. (Scheme 266)
2. Remove pencil strut. (Scheme 267)
3. Loosen the upper and lower torque strut attaching bolt at the suspension crossmember and shock tower bracket. (Scheme 265)
4. The engine position may now be adjusted by positioning a suitable floor jack on the forward edge of the transmission bell housing. (Scheme 268) NOTE: The floor jack must be positioned as shown in to prevent minimal upward lifting of the engine. (Scheme 268)
5. With the engine supported, remove the upper and lower torque strut attachment bolt(s) at shock tower bracket and suspension crossmember. (Scheme 265) 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
6. Carefully apply upward force, allowing the upper engine to rotate rearward until the distance between the center of the rearmost attaching bolt on the engine mount bracket (point "A") and the center of the hole on the shock tower bracket (point "B") is 119 mm (4.70 in.). (Scheme 269) CAUTION: The engine must be held in position with jack until both the upper and lower torque strut bolts are tightened.
7. With the engine held at the proper position, tighten both the upper and lower torque strut bolts to 115 N.m (85 ft. lbs.). (Scheme 265)
8. Remove the floor jack.
9. Install pencil strut and tighten nuts to 58 N.m (43 ft. lbs.). (Scheme 267)
10. Install accessory drive belt splash shield. (Scheme 266)

The lubrication system is a full-flow filtration, pressure feed type. The oil pump is mounted in the front engine cover and driven by the crankshaft.

Engine oil drawn up through the pickup tube and is pressurized by the oil pump and routed through the full-flow 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 main bearing journals to connecting rod journals. Balance shaft lubrication is provided through an oil passage from the number one main bearing cap through the balance shaft carrier support leg. This passage directly supplies oil to the front bearings and internal machined passages in the shafts that routes oil from front to the rear shaft bearing journals. A vertical hole at the number five bulkhead routes pressurized oil through a restrictor (integral to the cylinder head gasket) up past a cylinder head bolt to an oil gallery running the length of the cylinder head. The camshaft journals are partially slotted to allow a predetermined amount of pressurized oil to pass into the bearing cap cavities. Lubrication of the camshaft lobes are provided by small holes in the camshaft bearing caps that are directed towards each lobe. Oil returning to the pan from pressurized components supplies lubrication to the valve stems. Cylinder bores and wrist pins are splash lubricated from directed slots on the connecting rod thrust collars.

CHECKING ENGINE OIL PRESSURE

1. Disconnect and remove oil pressure switch. «(Refer to ENGINE/LUBRICATION/OIL PRESSURE SENSOR/SWITCH - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)
2. Install Special Tools C-3292 Gauge with 8406 Adaptor fitting.
3. Start engine and record oil pressure. «(Refer to ENGINE - SPECIFICATIONS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine) for correct oil pressure requirements. CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test
4. If oil pressure is 0 at idle. Shut off engine, check for pressure relief valve stuck open, a clogged oil pick-up screen or a damaged oil pick-up tube O-ring.
5. After test is complete, remove test gauge and fitting.
6. Install oil pressure switch and connector. «(Refer to ENGINE/LUBRICATION/OIL PRESSURE SENSOR/SWITCH - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine)

ENGINE OIL LEVEL CHECK

The best time to check engine oil level is after the vehicle has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level.

Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick ( (Scheme 270)or (Scheme 271) ) and observe oil level. Add oil only when the level is at or below the MIN mark. (Scheme 272)

Scheme 270

Scheme 271

Scheme 272

ENGINE OIL AND FILTER CHANGE

Change engine oil at mileage and time intervals described in the Maintenance Schedule (Refer to MAINTENANCE SCHEDULES .

Scheme 273

Scheme 274

1. Run engine until achieving normal operating temperature.
2. Position the vehicle on a level surface and turn engine off.
3. Remove oil fill cap. (Scheme 270)or (Scheme 271).
4. Raise vehicle on hoist.
5. Place a suitable oil collecting container under oil pan drain plug.
6. Remove oil pan drain plug. (Scheme 273)or (Scheme 274) and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged.
7. Remove oil filter. (Scheme 273)or (Scheme 274) «(Refer to ENGINE/LUBRICATION/OIL FILTER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine). 1 - OIL FILTER 2 - DRAIN PLUG 1 - OIL FILTER 2 - DRAIN PLUG
8. Install oil pan drain plug. Torque drain plug to 28 N.m (20 ft. lbs.).
9. Install new oil filter «(Refer to ENGINE/LUBRICATION/OIL FILTER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
10. Lower vehicle and fill crankcase with specified type and amount of engine oil «(Refer to LUBRICATION & MAINTENANCE/SPECIFICATIONS - FLUID CAPACITIES)»(/chrysler/pt-cruiser/i-2000-2010/remont/hoistjack/#lubrication-maintenance) and (Refer to «FLUID TYPES»(/chrysler/pt-cruiser/i-2000-2010/remont/hoistjack/#lubrication-maintenance) ).
11. Install oil fill cap or (Scheme 270) (Scheme 271).
12. Start engine and inspect for leaks.
13. Stop engine and inspect oil level.

OIL FILTER SPECIFICATION

All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar(R) or the equivalent.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above.

1. Using a suitable filter wrench, turn oil filter ( (Scheme 273)or (Scheme 274) ) counterclockwise to remove.

1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of gasket.
2. Lubricate new oil filter gasket.
3. Screw oil filter ( (Scheme 273)or (Scheme 274) ) on until the gasket contacts base. Tighten to 21 N.m (15 ft. lbs.).

1. Raise vehicle on hoist.
2. Place a suitable oil collecting container under oil filter.
3. Remove oil filter «(Refer to ENGINE/LUBRICATION/OIL FILTER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
4. Turbocharger Equipped Vehicles: Remove oil cooler connector bolt. DO NOT disconnect coolant lines from oil cooler. Reposition oil cooler.
5. Remove filter adapter attaching bolts. (Scheme 275)
6. Remove filter adapter and gasket. (Scheme 275)

Scheme 275

1. Clean all gasket sealing surfaces
2. Install gasket and filter adaptor to oil pan. (Scheme 275) Tighten bolts to 12 N.m (105 in. lbs.).
3. Turbocharger Equipped Vehicles: Replace oil cooler seal Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab Install oil cooler connector bolt. Torque connector bolt to 55 N.m (41 ft. lbs.)
4. Install oil filter «(Refer to ENGINE/LUBRICATION/OIL FILTER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
5. Lower vehicle and check engine oil level. Adjust level as necessary.

1. Raise vehicle on hoist.
2. Drain engine oil and remove oil filter.
3. Remove accessory drive belt splash shield.
4. Turbocharger Equipped Vehicles: Remove turbocharger to charge air cooler hose assembly «(Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/CHARGE AIR COOLER AND HOSES - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/blowers-superchargers-turbochargers/#exhaust-system-turbocharger).
5. Turbocharger Equipped Vehicles: Remove oil cooler connector bolt. DO NOT disconnect coolant lines from oil cooler. Reposition oil cooler.
6. Remove structural collar «(Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COLLAR - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
7. Remove lower torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
8. Remove oil filter adapter and gasket. (Scheme 276)
9. Remove oil pan and gasket. (Scheme 276)
10. Clean oil pan and all gasket surfaces.

Scheme 276

Scheme 277

1. Apply Mopar(R) Engine RTV GEN II at the oil pump to engine block parting lines. (Scheme 277) 1 - SEALER LOCATIONS
2. Install oil pan gasket to the block.
3. Install pan gasket and pan. Tighten screws to 12 N.m (105 in. lbs.).
4. Install oil filter adapter and gasket. (Scheme 276) Tighten screws to 12 N.m (105 in. lbs.).
5. Turbocharger Equipped Vehicles: Replace oil cooler seal Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab Install oil cooler connector bolt. Torque connector bolt to 55 N.m (41 ft. lbs.)
6. Install oil drain plug and oil filter.
7. Install structural collar «(Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COLLAR - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
8. Install lower torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
9. Turbocharger Equipped Vehicles: Install turbocharger to charge air cooler hose assembly «(Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/CHARGE AIR COOLER AND HOSES - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/blowers-superchargers-turbochargers/#exhaust-system-turbocharger).
10. Lower vehicle and fill engine crankcase with proper oil to correct level.

The oil pressure switch is located on the right rear side of the engine block. (Scheme 278) The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block).

The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig.

1. Raise vehicle.
2. Position oil collecting container under pressure switch location.
3. Disconnect oil pressure switch electrical connector and remove switch. (Scheme 278)

Scheme 278

1. Install oil pressure switch and connect electrical connector. (Scheme 278)
2. Lower vehicle.
3. Start engine and allow to run a minimum of 2 minutes.
4. Shut engine off and check engine oil level. Adjust level as necessary.

Scheme 279

Scheme 280

1. Disconnect negative cable from battery.
2. Remove timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Remove timing belt rear cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
4. Remove oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
5. Remove crankshaft sprocket using Special Tools 6793 and C-4685-C2. (Scheme 279)
6. Remove crankshaft key. (Scheme 280) 1 - SPECIAL TOOL 6793 2 - SPECIAL TOOL C-4685-C2 3 - CRANKSHAFT SPROCKET 1 - CRANKSHAFT KEY
7. Remove oil pick-up tube.
8. Remove oil pump and front crankshaft seal. (Scheme 281)

Scheme 281

DISASSEMBLY

1. Remove oil pump cover fasteners, and lift off cover. (Scheme 282)
2. Remove pump rotors. (Scheme 282)
3. Wash all parts in a suitable solvent and inspect carefully for damage or wear.

Scheme 282

Clean all parts thoroughly.

1. Inspect the mating surface of the oil pump. Surface should be smooth. Replace pump cover if scratched or grooved.
2. Lay a straightedge across the pump cover surface. (Scheme 283) If a 0.025 mm (0.001 in.) feeler gauge can be inserted between cover and straight edge, cover should be replaced.
3. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 10.699 mm (0.421 in.) or less, or if the diameter is 85.924 mm (3.383 in.) or less, replace outer rotor. (Scheme 284)
4. If inner rotor measures 10.699 mm (0.421 in.) or less replace inner rotor. (Scheme 285)

Scheme 283

Scheme 284

Scheme 285

ASSEMBLY

1. Assemble pump, using new parts as required. Install the inner rotor with chamfer facing the cast iron oil pump cover.
2. Prime oil pump before installation by filling rotor cavity with engine oil.
3. Install cover and tighten fasteners to 13 N.m (118 in. lbs.). (Scheme 282)

Scheme 286

1. Make sure all surfaces are clean and free of oil and dirt.
2. Apply Mopar(R) Gasket Maker to oil pump (Scheme 286) Install O-ring into oil pump body discharge passage. 1 - O-RING 2 - SEALER LOCATION
3. Prime oil pump with engine oil before installation.
4. Align oil pump rotor flats with flats on crankshaft. Install the oil pump to the block. (Scheme 281) CAUTION: To align, the front crankshaft seal MUST be out of pump, or damage may result.
5. Install new front crankshaft seal using Special Tool 6780. see scheme 155 1 - PROTECTOR 2 - SEAL 3 - SPECIAL TOOL 6780
6. Install crankshaft key. (Scheme 280) CAUTION: The crankshaft sprocket is set to a predetermined depth from the factory for correct timing belt tracking. If removed, use of Special Tool 6792 is required to set the sprocket to original installation depth. An incorrectly installed sprocket will result in timing belt and engine damage.
7. Install crankshaft sprocket using Special Tool 6792. see scheme 156 1 - SPECIAL TOOL 6792 2 - TIGHTEN NUT TO INSTALL
8. Install oil pump pick-up tube.
9. Install oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
10. Install timing belt rear cover «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
11. Install timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

The 2.4L Turbocharged engines are equipped with four oil jets installed in the engine block. The oil jets are provided engine oil pressure from the main oil gallery. The oil jets are used to cool the pistons. An integral check ball controls the flow of oil through the oil jet. (Scheme 287)

Scheme 287

1. Remove crankshaft «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Remove oil jet fastener. see scheme 158 CAUTION: Do Not Pull on Oil Jet Tube
3. Using pliers or other similar tool, pull oil jet from engine block.

1. Inspect oil jet o-ring. (Scheme 288)
2. Lightly coat o-ring with clean engine oil.
3. Push oil jet into engine block until it is fully seated. CAUTION: Ensure oil jet is fully seated in engine block before installing fastener. Do Not use the oil jet fastener to draw the oil jet into the engine block. Damage to oil jet may occur.
4. Install oil jet fastener. Torque fastener to 12 N.m (105 in. lbs.). see scheme 158
5. Install crankshaft «(Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

Scheme 288

An engine oil cooler is used on the 2.4L Turbocharged engine. The cooler is a coolant-to-oil type and mounted between the oil filter and oil filter adapter. (Scheme 289)

1. Raise vehicle on hoist.
2. 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).
3. Disconnect oil cooler coolant hoses. (Scheme 289)
4. Remove oil filter.
5. Remove oil cooler connector bolt. (Scheme 290)
6. Remove oil cooler.

Scheme 289

Scheme 290

1. Replace oil cooler seal. (Scheme 291)
2. Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab. (Scheme 292)
3. Install oil cooler connector bolt. Torque connector bolt to 55 N.m (41 ft. lbs.). (Scheme 290)
4. Install oil filter.
5. Connect oil cooler coolant hoses. (Scheme 289)
6. Lower vehicle.
7. 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).

Scheme 291

Scheme 292

INTAKE MANIFOLD LEAKS

An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.

1. Start the engine.
2. Spray a small stream of water (Spray Bottle) at the suspected leak area.
3. If engine RPM'S change, the area of the suspected leak has been found.
4. Repair as required.

Scheme 293

Scheme 294

Scheme 295

Scheme 296

Scheme 297

Scheme 298

1. Disconnect inlet air temperature sensor and make-up air hose from clean air hose. (Scheme 293)
2. Remove air cleaner housing and clean air hose assembly. 1 - MAKE-UP AIR HOSE 2 - PCV VALVE
3. Disconnect negative cable from battery.
4. Remove throttle and speed control cables from throttle lever and bracket.
5. Disconnect manifold absolute pressure (MAP) sensor, idle air control (IAC) motor and throttle position sensor (TPS) wiring connectors. (Scheme 294)and (Scheme 295). 1 - MAP SENSOR 1 - IAC 2 - PCM 3 - TPS
6. Disconnect proportional purge hoses. (Scheme 296)
7. Disconnect brake booster hose. (Scheme 297) 1 - PROPORTIONAL PURGE HOSES
8. Disconnect PCV hose from intake manifold. (Scheme 293)
9. Remove rear intake manifold support bracket. (Scheme 298) 1 - INTAKE MANIFOLD SUPPORT BRACKET
10. Remove upper intake manifold fasteners. (Scheme 307)
11. Remove upper intake manifold.
12. If further service is required, cover the lower intake manifold openings to prevent foreign materials from entering the engine. (Scheme 299)

Scheme 299

Note. This engine could be equipped with an aluminum Intake manifold or a plastic intake manifold.

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304

Scheme 305

Scheme 306

1. Disconnect negative battery cable.
2. Disconnect the inlet air temperature (IAT) sensor connector. (Scheme 300)
3. Disconnect the throttle inlet pressure (TIP) hose. (Scheme 300) 1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY 2 - IAT SENSOR 3 - TIP HOSE
4. Disconnect charge air cooler hose at throttle body. (Scheme 300)and see scheme 172. 1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY 2 - CHARGE AIR COOLER 3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
5. Disconnect idle air control (IAC) motor and throttle position sensor connectors.
6. Disconnect the MAP sensor connector. (Scheme 301) 1 - MAP SENSOR
7. Remove the throttle control shield. (Scheme 302)
8. Remove the throttle cable from the throttle body lever. (Scheme 303)
9. If equipped with speed control, remove speed control cable from the throttle lever by sliding clasp out hole used for throttle cable.
10. Remove the 2 screws for the throttle cable bracket.
11. Reposition throttle cable bracket. (Scheme 304)
12. Remove intake manifold cover. NOTE: To remove intake manifold cover, start with clips near throttle body.
13. Disconnect brake booster hose and PCV hose from intake manifold. (Scheme 305)
14. Disconnect purge solenoid hose from throttle body. (Scheme 305) 1 - PURGE SOLENOID HOSE 2 - BRAKE BOOSTER HOSE 3 - PCV HOSE
15. Remove intake manifold cover.
16. Remove upper intake manifold support bracket. (Scheme 306) 1 - FASTENERS 2 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
17. Remove upper intake manifold fasteners. (Scheme 308)
18. Remove upper intake manifold.
19. If further service is required, cover the lower intake manifold openings to prevent foreign materials from entering the engine. (Scheme 299)

LOWER INTAKE MANIFOLD

Note. Turbo charged engines could be equipped with either an aluminum or a plastic intake manifold.

1. Perform fuel system pressure release procedure before attempting any repairs «(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 UPPER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
4. Partially drain cooling system below thermostat level «(Refer to COOLING/ENGINE - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
5. Remove upper radiator hose.
6. Remove coolant outlet connector and thermostat «(Refer to COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
7. Disconnect the fuel supply line quick connect at the fuel rail assembly «(Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/fuel-system/#fuel-system). WARNING: WRAP SHOP TOWELS AROUND HOSE TO CATCH ANY GASOLINE SPILLAGE.
8. Disconnect fuel injector wiring harness.
9. Remove screw attaching the oil dipstick tube to lower intake manifold. see scheme 179or see scheme 180.
10. Turbocharger Equipped Engine: Remove fasteners for lower intake manifold support bracket. see scheme 180
11. Remove lower intake manifold fasteners. (Scheme 310)
12. Remove lower intake manifold.

1. Discard gasket(s).
2. Clean all sealing surfaces.

1. Inspect manifold for cracks, distortion, or mounting surface warpage. Replace manifold if necessary.
2. Inspect manifold gasket for surface damage or excessive swelling. Replace gaskets as necessary.

Scheme 307

1. If lower intake manifold was covered during service, remove cover. (Scheme 299)
2. Clean all sealing surfaces. Replace seals as necessary.
3. Position new seals on manifold.
4. Position upper intake manifold on lower intake manifold. Tighten upper intake manifold fasteners to 12 N.m (105 in. lbs.) in sequence (Scheme 307)
5. Connect PCV hose to intake manifold. see scheme 182 1 - MAKE-UP AIR HOSE 2 - PCV VALVE
6. Connect manifold absolute pressure (MAP) electrical connector. (Scheme 294)
7. Connect proportional purge hoses. (Scheme 296)
8. Connect brake booster hose. (Scheme 297)
9. Connect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors. (Scheme 295)
10. Install throttle and speed control cables to bracket. Connect cables to the throttle lever.
11. Connect negative cable to battery.
12. Install air cleaner housing and clean air hose. Tighten clean air hose clamp to 1.7 N.m (15 in. lbs.).
13. Connect make-up air hose and inlet air temperature sensor. see scheme 182

Scheme 308

1. If lower intake manifold was covered during service, remove cover. (Scheme 299)
2. Clean all sealing surfaces. Replace upper intake manifold gasket. NOTE: This engine could be equipped with either a plastic intake manifold or an aluminum intake manifold.
3. Position upper intake manifold on lower intake manifold. On engines equipped with an aluminum intake manifold, tighten manifold fasteners to 28 N.m (250 in. lbs.) in sequence (Scheme 308) On engines equipped with a plastic intake manifold, tighten manifold fasteners to 12 N.m (105 in. lbs.) in sequence shown in. (Scheme 308)
4. Install upper intake manifold to cylinder head support bracket. (Scheme 306) Torque cylinder head fasteners to 28 N.m (250 in. lbs.) and manifold fasteners to 6 N.m (55 in. lbs.).
5. Install the intake manifold cover.
6. Connect purge solenoid hose to throttle body. (Scheme 305)
7. Connect brake booster vacuum hose and PCV hose to intake manifold. (Scheme 305)
8. Install the 2 screws for the throttle cable bracket and tighten to 12 N.m (105 in. lbs.) on aluminum intake manifolds and 6 N.m (55 in. lbs.) on plastic intake manifolds.
9. If equipped with speed control, install speed control cable to the throttle lever by sliding clasp in the hole used for throttle cable.
10. Install the throttle cable to the throttle body lever. (Scheme 303)
11. Install the throttle control shield. (Scheme 302)
12. Connect idle air control (IAC) motor and throttle position sensor connectors.
13. Connect the MAP sensor connector. (Scheme 301)
14. Connect charge air cooler hose to throttle body. (Scheme 300)and see scheme 172. Tighten hose clamp to 1.7 N.m (15 in. lbs.).
15. Connect negative battery cable.

Note. Turbo charged engines could be equipped with either an aluminum or a plastic manifold.

Scheme 309

Scheme 310

1. Clean all gasket surfaces.
2. Naturally Aspirated Engine: Position new seals on lower intake manifold. (Scheme 309)
3. Naturally Aspirated Engine: Install lower intake manifold. Tighten fasteners to 12 N.m (105 in. lbs.) in sequence (Scheme 310)
4. Turbocharged Engine: Replace lower intake manifold gasket.
5. Turbocharged Engine: Install lower intake manifold. If equipped with an aluminum manifold, tighten fasteners to 28 N.m (250 in. lbs.) in sequence (Scheme 310) If equipped with a plastic manifold, tighten fasteners to 12 N.m (105 in. lbs.) in sequence (Scheme 310)1 - SEALS
6. Turbocharger Equipped Engine: Install fasteners for lower intake manifold support bracket. see scheme 180 If equipped with an aluminum manifold, torque fasteners to 54 N.m (40 ft. lbs.). If equipped with a plastic manifold, torque manifold fasteners to 6 N.m (55 in. lbs.).
7. If removed, install the fuel rail assembly to intake manifold. Tighten screws to 23 N.m (200 in. lbs.).
8. Connect fuel injector wiring harness.
9. Inspect quick connect fittings for damage, replace if necessary «(Refer to FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STANDARD PROCEDURE)»(/chrysler/pt-cruiser/i-2000-2010/remont/fuel-system/#fuel-system). Lubricate tube with clean engine oil. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.
10. Install the screw attaching the oil dipstick tube to lower intake manifold. see scheme 179or see scheme 180.
11. Install coolant outlet connector and thermostat «(Refer to COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
12. Install radiator upper hose.
13. Install upper intake manifold «(Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD UPPER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
14. Connect negative cable to battery.
15. 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).
16. With the DRBIII(R) scan tool use ASD Fuel System Test to pressurize system to check for leaks.

Note. The exhaust manifold on Turbocharged equipped vehicles is serviced as an assembly with the Turbocharger. (Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - REMOVAL) .

Scheme 311

Scheme 312

Scheme 313

Scheme 314

1. Remove clean air hose and air cleaner housing.
2. Disconnect negative cable from battery.
3. Disconnect throttle and speed control cables from the throttle lever and bracket.
4. Disconnect MAP sensor electrical connector.
5. Remove fasteners securing power steering fluid reservoir to cylinder head.
6. Remove coolant recovery container «(Refer to COOLING/ENGINE/COOLANT RECOVERY CONTAINER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
7. Remove bolts attaching upper heat shield. (Scheme 311)
8. Remove upper heat shield. 1 - BOLTS
9. Raise vehicle.
10. Disconnect exhaust pipe from manifold. see scheme 187 1 - GASKET 2 - CATALYTIC CONVERTER 3 - NUT
11. Remove engine wiring heat shield. (Scheme 312) 1 - HEAT SHIELD 2 - NUT 3 - NUT
12. Remove manifold support bracket. (Scheme 313)
13. Remove lower exhaust manifold heat shield. (Scheme 314) 1 - UPPER HEAT SHIELD 2 - LOWER HEAT SHIELD
14. Disconnect oxygen sensor electrical connector.
15. Remove exhaust manifold lower retaining fasteners.
16. Lower vehicle and remove the upper exhaust manifold retaining fasteners.
17. Remove exhaust manifold from above/between the engine and cowl panel. (Scheme 315)
18. Remove and discard manifold gasket.

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.

Note. The exhaust manifold on Turbocharged equipped vehicles is serviced as an assembly with the Turbocharger. (Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - INSTALLATION) .

Scheme 315

1. Install a new exhaust manifold gasket. DO NOT APPLY SEALER.
2. Position exhaust manifold in place. Tighten fasteners, starting at center and progressing outward in both directions to 23 N.m (200 in. lbs.). (Scheme 315) Raise and lower vehicle for fastener access as necessary. Repeat tightening procedure until all fasteners are at specified torque.
3. Install exhaust manifold heat shields. (Scheme 314) Tighten bolts to 12 N.m (105 in. lbs.). (Scheme 311)
4. Install exhaust manifold support bracket. (Scheme 313)
5. Install engine wiring heat shield. (Scheme 312)
6. Connect oxygen sensor electrical connector.
7. Install exhaust pipe to manifold. see scheme 187 Tighten fasteners to 28 N.m (250 in. lbs.).
8. Install coolant recovery container «(Refer to COOLING/ENGINE/COOLANT RECOVERY CONTAINER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/accessory-drive-belts/#engine-cooling-system-automatic-transmission-cooling-system).
9. Install fasteners securing power steering fluid reservoir to cylinder head.
10. Connect MAP sensor electrical connector.
11. Connect throttle and speed control cables to the throttle lever and bracket.
12. Connect negative cable to battery.
13. Install clean air hose and air cleaner housing.

FRONT COVER-UPPER

1. Remove upper torque strut attaching bolts and set strut aside «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Turbocharger equipped vehicles: Discharge and evacuate and air conditioning system (Refer to «HEATING & AIR CONDITIONING»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information) ). Disconnect air conditioning lines at junction block near upper timing belt cover.
3. Remove upper timing belt cover fasteners and remove cover. (Scheme 316)

Scheme 316

FRONT COVER-LOWER

1. Disconnect negative battery cable.
2. Raise vehicle on hoist. Remove right front wheel.
3. Remove the right splash shield.
4. Remove accessory drive belts «(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).
5. Remove crankshaft damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
6. Remove the lower torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
7. Disconnect exhaust system from manifold.
8. Disconnect A/C pressure switch at rear of compressor housing.
9. Lower vehicle and support engine with a jack.
10. Discharge A/C system and disconnect A/C lines at coupling block (Refer to «HEATING & AIR CONDITIONING»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information) ).
11. Remove upper torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
12. Remove screw attaching ground strap to strut bracket.
13. Remove torque strut bracket from strut tower.
14. Remove upper radiator closure panel «(Refer to BODY/EXTERIOR/RADIATOR CLOSURE PANEL- REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
15. Remove power steering pump and bracket. Set pump aside. Do not disconnect lines from pump.
16. With engine properly supported, remove right engine mount through bolt.
17. Raise engine with jack until engine support bracket bolts are accessible. (Scheme 317)
18. Remove engine support bracket. (Scheme 317)
19. Remove timing belt cover fasteners and remove cover. (Scheme 316)

Scheme 317

Scheme 318

1. Remove front timing belt covers. Refer to above procedures.
2. Remove timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Remove timing belt idler pulley. (Scheme 318) 1 - IDLER PULLEY 2 - BOLT
4. Remove camshaft sprockets. Use Special Tool 6847 to hold camshaft sprockets while removing the sprocket bolts. see scheme 195 1 - SPECIAL TOOL 6847
5. Remove rear timing belt cover fasteners and remove cover from engine. (Scheme 319)

Scheme 319

1. Install timing belt cover and tighten fasteners to 6 N.m (50 in. lbs.). (Scheme 316)
2. Install upper torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Turbocharger equipped vehicles: Connect air conditioning lines at junction block near upper timing belt cover. Recharge air conditioning system (Refer to «HEATING & AIR CONDITIONING»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information) ).
4. Perform torque strut adjustment procedure «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

1. Install lower timing belt cover and tighten fasteners to 6 N.m (50 in. lbs.). (Scheme 316)
2. Install right engine support bracket. (Scheme 317) Ensure the power steering pump is properly located in mounting location on bracket. Tighten mount bracket bolts to 61 N.m (45 ft. lbs.).
3. Lower engine into mounting position and install right engine mount through bolt. Tighten bolt to 118 N.m (87 ft. lbs.).
4. Install power steering pump and bracket.
5. Install upper radiator closure panel «(Refer to BODY/EXTERIOR/RADIATOR CLOSURE PANEL- INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/gauges-instrument-panels/#interior-exterior).
6. Install torque strut bracket to strut tower.
7. Connect ground strap to bracket.
8. Install upper torque strut.
9. Connect A/C lines and charge A/C system (Refer to «HEATING & AIR CONDITIONING»(/chrysler/pt-cruiser/i-2000-2010/remont/general-servicing-all-makes/#hvac-systems-service-information) ).
10. Raise vehicle.
11. Connect exhaust system to manifold.
12. Connect A/C pressure switch connector.
13. Install crankshaft damper «(Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
14. Install accessory drive belts «(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).
15. Install lower torque strut «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
16. Perform torque strut adjustment procedure «(Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
17. Install right splash shield.
18. Install right front wheel.
19. Connect negative cable to battery.

REAR COVER

1. Install rear timing belt cover and fasteners. Torque fasteners to values specified in. (Scheme 319)
2. Install timing belt idler pulley. (Scheme 318) Torque timing belt idler pulley fastener to 61 N.m (45 ft. lbs.). CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin may occur.
3. Install camshaft sprockets. Hold sprockets with Special Tool 6847 while tightening center bolt to 115 N.m (85 ft. lbs.). see scheme 195
4. Install timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
5. Install front timing belt covers. Refer to above procedures.

Scheme 320

1. Disconnect negative battery cable.
2. Remove upper and lower front timing belt covers. (Scheme 316) «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine). CAUTION: When aligning crankshaft and camshaft timing marks always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt.
3. Before the removal of the timing belt, rotate crankshaft until the TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth). (Scheme 320) NOTE: The crankshaft sprocket TDC mark is located on the trailing edge of the sprocket tooth. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause the camshaft timing marks to be misaligned. 1 - CAMSHAFT TIMING MARKS 2 - CRANKSHAFT TDC MARKS 3 - TRAILING EDGE OF SPROCKET TOOTH
4. Loosen timing belt tensioner lock bolt. (Scheme 321)
5. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. (Scheme 321) Rotate the top plate CLOCKWISE until there is enough slack in timing belt to allow for removal.
6. Remove timing belt.

Scheme 321

CAMSHAFT SPROCKET(S)

1. Remove upper and lower front timing belt covers «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Remove timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Use Special Tool 6847 to hold camshaft sprockets while removing the sprocket bolt(s). see scheme 199 Remove camshaft sprocket(s).

CRANKSHAFT SPROCKET

1. Remove upper and lower front timing belt covers «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Remove timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Remove crankshaft sprocket using Special Tool 6793 and insert C-4685-C2. see scheme 200

1. Install crankshaft sprocket using Special Tool 6792. see scheme 201
2. Install timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Install upper and lower front timing belt covers «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

1. Install camshaft sprockets. Hold sprockets with Special Tool 6847 while tightening center bolt to 115 N.m (85 ft. lbs.). see scheme 199
2. Install timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Install upper and lower front timing belt covers «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

Scheme 322

Scheme 323

Scheme 324

Scheme 325

1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing.
2. Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket. (Scheme 322) CAUTION: Ensure that the arrows on both camshaft sprockets are facing up. 1 - CAMSHAFT SPROCKET-EXHAUST 2 - CAMSHAFT SPROCKET-INTAKE 3 - 1/2 NOTCH LOCATION
3. Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner. (Scheme 323)
4. Move the exhaust camshaft sprocket counterclockwise to align marks and take up belt slack. (Scheme 323) 1 - CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION 2 - CRANKSHAFT AT TDC 3 - INSTALL BELT IN THIS DIRECTION 4 - ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK
5. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate COUNTERCLOCKWISE. The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang. (Scheme 324) Using the allen wrench to prevent the top plate from moving, torque the tensioner lock bolt to 25 N.m (220 in. lbs.). Setting notch and spring tang should remain aligned after lock bolt is torqued.
6. Remove allen wrench and torque wrench. 1 - ALIGN SETTING NOTCH WITH SPRING TANG 2 - TOP PLATE 3 - 6mm ALLEN WRENCH 4 - LOCK BOLT 5 - SETTING NOTCH 6 - SPRING TANG NOTE: Repositioning the crankshaft to the TDC position must be done only during the CLOCKWISE rotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise as this will make verification of proper tensioner setting impossible.
7. Rotate the crankshaft CLOCKWISE two complete revolutions manually for seating of the belt, until the crankshaft is repositioned at the TDC position. Verify that the camshaft and crankshaft timing marks are in proper position. see scheme 205 1 - CAMSHAFT TIMING MARKS 2 - CRANKSHAFT TDC MARKS 3 - TRAILING EDGE OF SPROCKET TOOTH
8. Check if the spring tang is within the tolerance window. (Scheme 325) If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang is not within the tolerance window, repeat Steps 5 through 7. 1 - SPRING TANG 2 - TOLERANCE WINDOW
9. Install upper and lower front timing belt covers. (Scheme 316) «(Refer to ENGINE/VALVE TIMING/TIMING BELT COVER(S) - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
10. Connect negative cable to battery.

1. Remove timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
2. Remove timing belt idler pulley.
3. Hold camshaft sprocket with Special Tool 6847 while removing bolt. see scheme 207 Remove both camshaft sprockets. 1 - SPECIAL TOOL 6847 1 - M6 BOLTS - 12 N.m (105 in. lbs.) 2 - M8 BOLTS - 28 N.m (250 in. lbs.) 3 - TIMING BELT TENSIONER
4. Remove rear timing belt cover fasteners and remove cover from engine. see scheme 208
5. Remove lower bolt attaching timing belt tensioner assembly to engine and remove tensioner as an assembly. (Scheme 326)

Scheme 326

1. Align timing belt tensioner assembly to engine and install lower mounting bolt but do not tighten. (Scheme 326) To properly align tensioner assembly to engine; temporarily install one of the engine bracket mounting bolts (M10) 5-7 turns into the tensioner assembly upper mounting location. (Scheme 326)
2. Torque the tensioner's lower mounting bolt to 61 N.m (45 ft. lbs.). Remove the upper bolt used for tensioner alignment. 1 - BOLT 2 - TENSIONER ASSEMBLY 3 - BOLT-INSTALL FOR PROPER ALIGNMENT
3. Install rear timing belt cover and fasteners. see scheme 208
4. Install timing belt idler pulley and torque mounting bolt to 61 N.m (45 ft. lbs.). CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin may occur.
5. Install camshaft sprockets. Use Special Tool 6847 to hold sprockets and tighten bolts to 115 N.m (85 ft. lbs.). see scheme 207
6. Install timing belt «(Refer to ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).

The 2.4L engine is equipped with two nodular cast iron balance shafts installed in a cast aluminum carrier attached to the lower cylinder block. (Scheme 327)

Scheme 327

The balance shafts are driven by the crankshaft via a roller chain and sprockets. The balance shafts are connected by helical gears. The dual counter rotating shafts decrease second order vertical shaking forces caused by component movement.

BALANCE SHAFTS/CHAIN/SPROCKETS

Note. For service procedures requiring only temporary relocation of carrier assembly refer to BALANCE SHAFT CARRIER .

Scheme 328

Scheme 329

Scheme 330

Scheme 331

1. Drain engine oil.
2. Remove the oil pan and pick-up tube «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. If replacing crankshaft sprocket, remove oil pump «(Refer to ENGINE/LUBRICATION/OIL PUMP - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine). 1 - STUD 2 - TENSIONER (ADJUSTER) 3 - GEAR COVER 4 - ADJUSTER SCREW 5 - SHOULDERED PIVOT SCREW 6 - CHAIN COVER (CUTAWAY) 7 - GUIDE
4. Remove chain cover, guide and tensioner. Discard pivot screw and adjuster screw. (Scheme 328)
5. Remove screw retaining balance shaft drive sprocket. (Scheme 329) Remove chain and sprocket.
6. Using two wide pry bars, work the crankshaft sprocket back and forth until it is off the crankshaft. 1 - NICKEL PLATED LINK AND MARK 2 - GEAR/SPROCKET SCREWS 3 - NICKEL PLATED LINK AND DOT
7. Remove gear cover retaining stud (double ended to also retain chain guide). Remove cover and balance shaft gears. (Scheme 330) 1 - STUD (DOUBLE ENDED) 2 - DRIVE GEAR 3 - DRIVEN GEAR 4 - CARRIER DOWEL 5 - GEAR(S) 6 - GEAR COVER 1 - REAR COVER 2 - CARRIER 3 - BALANCE SHAFT
8. Remove rear cover and balance shafts. (Scheme 331)
9. Remove four carrier to crankcase attaching bolts to separate carrier from engine bedplate.

BALANCE SHAFT CARRIER

The following components will remain intact during carrier removal: Gear cover, gears, balance shafts and the rear cover. (Scheme 327)

1. Drain engine oil.
2. Remove the oil pan and pick-up tube «(Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
3. Remove chain cover, guide and tensioner. (Scheme 328)
4. Remove screw retaining balance shaft drive sprocket. (Scheme 329)
5. Move balance shaft inboard through drive chain sprocket. Sprocket will hang in lower chain loop.
6. Remove carrier to crankcase attaching bolts to remove carrier.

BALANCE SHAFT INSTALLATION/TIMING

Balance shaft and carrier assembly installation is the reverse of the removal procedure. During installation crankshaft-to-balance shaft timing must be established. Refer to Timing procedure in this article.

Scheme 332

Scheme 333

Scheme 334

Scheme 335

1. With balance shafts installed in carrier position carrier on crankcase and install four attaching bolts and tighten to 54 N.m (40 ft. lbs.). (Scheme 327)
2. Turn balance shafts until both shaft key ways are up, parallel to vertical centerline of engine. Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft. After installation gear and balance shaft keyways must be up with gear timing marks meshed (Scheme 332) 1 - KEY WAYS UP 2 - GEAR ALIGNMENT DOTS
3. Install gear cover and tighten double ended stud/washer fastener to 12 N.m (105 in. lbs.).
4. Align flat on balance shaft drive sprocket to the flat on crankshaft. (Scheme 333)
5. Install balance shaft drive sprocket on crankshaft using Special Tool 6052. (Scheme 334) 1 - ALIGN FLATS 1 - SPROCKET 2 - SPECIAL TOOL 6052
6. Turn crankshaft until number 1 cylinder is at top dead center (TDC). The timing marks on the chain sprocket should line up with the parting line on the left side of number one main bearing cap. (Scheme 335)
7. Place chain over crankshaft sprocket so that the plated link of the chain is over the number 1 cylinder timing mark on the balance shaft crankshaft sprocket. (Scheme 335)
8. Place balance shaft sprocket into the timing chain and align the timing mark on the sprocket (dot) with the (lower) plated link on the chain. (Scheme 335) NOTE: The lower plated link is 8 links from the upper link.
9. With balance shaft keyways pointing up (12 o'clock) slide the balance shaft sprocket onto the nose of the balance shaft. The balance shaft may have to be pushed in slightly to allow for clearance. 1 - MARK ON SPROCKET 2 - KEYWAYS UP 3 - ALIGN MARKS 4 - PLATED LINK 5 - PARTING LINE (BEDPLATE TO BLOCK) 6 - PLATED LINK NOTE: THE TIMING MARK ON THE SPROCKET, THE (LOWER) NICKEL PLATED LINK, AND THE ARROW ON THE SIDE OF THE GEAR COVER SHOULD LINE UP WHEN THE BALANCE SHAFTS ARE TIMED CORRECTLY.
10. If the sprockets are timed correctly, install the balance shaft bolts and tighten to 28 N.m (250 in. lbs.). A wood block placed between crankcase and crankshaft counterbalance will prevent crankshaft and gear rotation.
11. CHAIN TENSIONING: Install chain tensioner loosely assembled with new adjuster screw and shouldered pivot screw. Position guide on double ended stud making sure tab on the guide fits into slot on the gear cover. Install and tighten nut/washer assembly to 12 N.m (105 in. lbs.). Place a shim 1 mm (0.039 in.) thick x 70 mm (2.75 in.) long between tensioner and chain. Push tensioner and shim up against the chain. Apply firm pressure 2.5-3 Kg (5.5-6.6 lbs.) directly behind the adjustment slot to take up all slack. Chain must have shoe radius contact (Scheme 336) With the load applied, tighten top tensioner adjuster bolt first, then bottom shouldered pivot bolt. Tighten bolts to 12 N.m (105 in. lbs.). Remove shim. Install carrier covers and tighten screws to 12 N.m (105 in. lbs.).
12. If removed, install oil pump «(Refer to ENGINE/LUBRICATION/OIL PUMP - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
13. Install pick-up tube and oil pan «(Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)»(/chrysler/pt-cruiser/i-2000-2010/remont/mechanical/#24l-dohc-engine).
14. Fill engine crankcase with proper oil to correct level.

Scheme 336

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 ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL)
• (Refer to COOLING/ENGINE - STANDARD PROCEDURE)
• HEATING & AIR CONDITIONING
• (Refer to BODY/EXTERIOR/GRILLE - REMOVAL)
• (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)
• (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)
• (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)
• (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION)
• (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION)
• (Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/LINES AND HOSES - REMOVAL)
• (Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/LINES AND HOSES - INSTALLATION)
• OVERHAUL - G288
• OVERHAUL - T350
• MAINTENANCE SCHEDULES
• (Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - REMOVAL)
• (Refer to EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - INSTALLATION)
• ENGINE DIAGNOSIS - PERFORMANCE
• ENGINE DIAGNOSIS - MECHANICAL
• CYLINDER COMPRESSION PRESSURE TEST
• CYLINDER COMBUSTION PRESSURE LEAKAGE TEST
• CYLINDER HEAD GASKET
• INTAKE MANIFOLD LEAKS
• HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS
• ENGINE OIL LEAK INSPECTION
• (Refer to ENGINE - SPECIAL TOOLS)
• INSPECTION FOR REAR SEAL AREA LEAKS
• CLEANING
• INSPECTION
• (Refer to ENGINE - REMOVAL)
• (Refer to ENGINE - INSTALLATION)
• BALANCE SHAFT CARRIER