Content .. 207 208 209 210 ..

Chrysler PT Cruiser. Manual - part 209

(4) Remove timing chain cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)

(5) Remove rear crankshaft seal adapter(Refer to 9

ENGINE/ENGINE

BLOCK/CRANKSHAFT

OIL

SEAL - REAR - REMOVAL).

(6) Remove piston and connecting rod assemblies

(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON &
CONNECTING ROD - REMOVAL).

CAUTION: The crankshaft bearing caps are num-
bered consecutively, beginning with the first crank-
shaft bearing cap at the front of engine. Attention
must be paid to the way crankshaft bearing caps fit.

(7) Unbolt crankshaft bearing caps (Fig. 25).

(8) Inspect crankshaft bearing caps and bolts for

wear and stretching.

(9) Remove crankshaft from engine block.

INSTALLATION

CAUTION: Oil bearing shells before inserting crank-
shaft.

CAUTION: Oil grooves in thrust washers must point
toward the thrust collars of the crankshaft.

CAUTION: Thrust washers in bearing cap each have
two retaining lugs as a anti-twist lock.

CAUTION: Oil thread and head contact surfaces of
bolts that retain crankshaft bearing caps; tighten
bolts from inside to outside, beginning at fit bear-
ing. Rotate crankshaft to check clearance.

(1) Install bearing halves into engine block.
(2) Install crankshaft into engine block..
(3) Install bearing halves into bearing caps.
(4) Install crankshaft bearing caps.Tighten bolts in

two stages. 55N·m (40.5 lbs ft), then 90°.

(5) Install piston and connecting rod assemblies

(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON &
CONNECTING ROD - INSTALLATION).

(6) Install rear crankshaft seal adapter (Refer to 9

ENGINE/ENGINE

BLOCK/CRANKSHAFT

OIL

SEAL - REAR - INSTALLATION).

(7) Install

timing

chain

cover

(Refer

ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).

(8) Install the engine (Refer to 9 - ENGINE -

INSTALLATION).

(9) Fill crankcase with the correct engine oil, to

the proper level. Refer to the owners manual for
specifications.

(10) Fill cooling system with the proper coolant, to

the proper level (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).

(11) Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR FAN. DO
NOT WEAR LOOSE CLOTHES.

(12) Start engine and inspect for leaks.

Fig. 25 Crankshaft Assembly - Typical

1 - BEARING HALVES IN ENGINE BLOCK
2 - THRUST WASHERS IN ENGINE BLOCK
3 - CRANKSHAFT
4 - BEARING HALVES IN MAIN BEARING CAPS
5 - MAIN BEARING CAPS
6 - THRUST WASHERS IN MAIN BEARING CAPS
7 - MAIN BEARING BOLTS

9 - 32

ENGINE

CRANKSHAFT (Continued)

(13) Install engine cover (Refer to 9 - ENGINE

COVER - INSTALLATION).

CRANKSHAFT OIL SEAL -
REAR

REMOVAL

This must be done with the transmission removed

from the vehicle.

(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle.
(3) Remove transmission assembly (Refer to 21 -

TRANSMISSION/TRANSAXLE/MANUAL

REMOVAL).

(4) Drain the engine oil.

NOTE: Loosen all of the oil pan bolts to assure that
the oil pan gasket is not damaged when removing
the rear main oil seal and adapter assembly.

NOTE: Inspect the oil pan gasket for damage. If the
oil pan gasket is damaged, remove oil pan and
replace oil pan gasket.

(5) Loosen oil pan bolts.
(6) Remove flywheel.

CAUTION: Care must be taken when removing the
rear main seal and adaptor assembly. Failure to do
so will result in damage to the oil pan gasket.

(7) Remove

the

rear

crankshaft

seal

adaptor

retaining bolts and carefully pry adaptor from crank-
case at adaptor shoulders (Fig. 26).

INSTALLATION

NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.

NOTE: Carefully position the rear main seal/adaptor
evenly onto the assembly sleeve. The rear main oil
seal lip MUST NOT roll over the edge of the tool.

(1) Position the rear crankshaft oil seal adaptor

with seal installer (special tool #8944) on crankshaft
so that the dowel sleeves fit into guide holes (Fig.
26). Care must be taken so that oil pan gasket is not
damaged.

Fig. 26 Rear Crankshaft Seal/Adapter

1 - FLYWHEEL
2 - FLYWHEEL BOLTS
3 - SPECIAL TOOL #8944
4 - REAR CRANKSHAFT OIL SEAL
5 - REAR CRANKSHAFT SEAL ADAPTER

6 - CRANKSHAFT
7 - ALIGNMENT DOWELS
8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER
RETAINING BOLT

ENGINE

9 - 33

CRANKSHAFT (Continued)

(2) Install the rear crankshaft seal/adaptor to crank-

case bolts and tighten to 9·Nm (80 lbs.in) (Fig. 26).

(3) Tighten the M6 oil pan bolts to 9N·m (80 lbs

in) and the M8 bolts to 20 N·m (15 lbs ft).

(4) Install fly wheel and tighten bolts in two stages

(Fig. 26). 45N·m (33 lbs. ft.) then 90°.

(5) Install transmission assembly (Refer to 21 -

TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION).

(6) Install the oil pan drain plug and tighten to

25N·m (18 lbs ft).

(7) Lower vehicle.
(8) Fill crankcase with the correct engine oil, to

the proper level. Refer to owners manual for specifi-
cations.

(9) Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE

OPERATING.

NOT

PUT

YOUR

HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.

(10) Start engine and inspect for leaks.
(11) Install engine cover (Refer to 9 - ENGINE

COVER - INSTALLATION).

VACUUM PUMP

DESCRIPTION

The vacuum pump is mounted to the rear of the

cylinder head next to the injection pump (Fig. 27).
The vacuum pump is of the vane type. The pump
supplies vacuum to the brake booster, EGR system,
turbocharger wastegate solenoid, and the swirl valve
actuator

REMOVAL

(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE

COVER - REMOVAL).

(3) Remove air cleaner housing assembly (Refer to

9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - REMOVAL).

(4) Disconnect vacuum hose from vacuum pump.
(5) Disconnect PDC from bracket and reposition

out of way.

(6) Remove vacuum pump retaining bolts and

remove pump from cylinder head.

INSTALLATION

(1) With o-ring installed on vacuum pump (Fig.

28), align pump with pump drive on camshaft.

(2) Slide vacuum pump into cylinder head and install

retaining bolts. Torque bolts to 14N·m (124 lbs. in.).

(3) Reposition

and

connect

PDC

mounting

bracket.

(4) Connect vacuum hose to vacuum pump.

(5) Install air cleaner housing assembly (Refer to 9

- ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).

(6) Install engine cover (Refer to 9 - ENGINE

COVER - INSTALLATION).

(7) Connect negative battery cable.

Fig. 27 Vacuum Pump Location

1 - VACUUM PUMP
2 - PDC
3 - INJECTION PUMP

Fig. 28 Vacuum Pump O-ring

1 - VACUUM PUMP
2 - O-RING

9 - 34

ENGINE

CRANKSHAFT OIL SEAL - REAR (Continued)

OIL PRESSURE SENSOR/
SWITCH

DESCRIPTION

The oil pressure switch is located on the right front

side of the engine block (Fig. 29). 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 single terminal device.

OPERATION

The oil pressure switch is normally “Closed.” The

switch changes from a

9Closed9 circuit to an 9Open9

circuit, on increasing pressure of 7 psig. The oil pres-
sure switch changes from an

9Open9 circuit to a

9Closed9 circuit, on decreasing pressure, between 2
psig and 4 psig.

OIL PAN

REMOVAL

(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove right front wheel.
(4) Remove engine compartment lower silencer

and accessory drive belt splash shield (Fig. 30).

(5) Drain engine oil.
(6) Remove power steering line to oil pan retaining

bolts.

(7) Disconnect power steering line from steering

gear and reposition out of way.

(8) Remove charge air cooler pipe to oil pan retain-

ing bolts.

(9) Disconnect charge air cooler pipe from turbo-

charger and reposition out of way.

(10) Remove oil cooler/filter assembly retaining

bolts and reposition assembly out of way (Fig. 31).

Fig. 29 Oil Pressure Sensor Location

1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - OIL PRESSURE SWITCH

Fig. 30 Engine Compartment Lower Silencer

1 - ENGINE COMPARTMENT SILENCER
2 - ACCESSORY DRIVE BELT SPLASH SHIELD

Fig. 31 Oil Cooler/FilterAssembly

1 - OIL COOLER
2 - LOWER TORQUE STRUT
3 - OIL PAN
4 - OIL FILTER HOUSING

ENGINE

9 - 35

Content .. 207 208 209 210 ..