Content .. 704 705 706 707 ..

Chrysler PT Cruiser. Manual - part 706

• Remove turbocharger support bracket

• Remove elbow

(15) Turbocharger equipped vehicles: (Refer to

11 - EXHAUST SYSTEM/TURBOCHARGER SYS-
TEM/LINES AND HOSES - REMOVAL) (Fig. 27).

• Remove oil return tube

• Remove oil supply line

• Remove coolant supply line

• Remove coolant return line
(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 9 - ENGINE/VALVE TIMING/TIMING
BELT AND SPROCKETS - REMOVAL).

(19) Remove timing belt idler pulley and rear tim-

ing belt cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - REMOVAL).

(20) Non-Turbo equipped vehicles: Remove fas-

teners securing power steering pump fluid reservoir/
bracket to cylinder head.

(21) Remove cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER - REMOVAL).

(22) Remove camshafts (Refer to 9 - ENGINE/

CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).

(23) Remove rocker arms.

(24) Remove cylinder head bolts in the reverse

sequence of tightening (Fig. 33).

(25) Remove cylinder head from engine block.
(26) Inspect and clean cylinder head and block

sealing surfaces. Refer to Cleaning and Inspection in
this section 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 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.

Clean all engine oil passages.

Fig. 26 Turbocharger Brackets and Heat Shields

1 - UPPER/LOWER HEAT SHIELDS
2 - TURBOCHARGER SUPPORT BRACKET
3 - ELBOW
4 - ELBOW SUPPORT BRACKET

Fig. 27 Turbocharger Lines and Hoses

1 - OIL SUPPLY LINE
2 - COOLANT RETURN LINE
3 - COOLANT SUPPLY LINE
4 - OIL RETURN TUBE

9 - 104

ENGINE 2.4L DOHC

CYLINDER HEAD (Continued)

INSPECTION

(1)

Cylinder head must be flat within 0.1 mm

(0.004 in.) (Fig. 28).

(2)

Inspect camshaft bearing journals for scoring.

(3) Remove carbon and varnish deposits from

inside of valve guides with a reliable guide cleaner.

(4) Using a small hole gauge and a micrometer,

measure valve guides in 3 places top, middle and bot-
tom (Fig. 29). (Refer to 9 - ENGINE - SPECIFICA-
TIONS) Replace guides if they are not within
specification.

(5) Check valve guide height (Fig. 30).

INSTALLATION - CYLINDER HEAD

NOTE: The Cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolts should be replaced (Fig. 31).

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.

Fig. 28 Checking Cylinder Head Flatness

1 - FEELER GAUGE
2 - STRAIGHT EDGE

Fig. 29 Checking Wear on Valve Guide—Typical

1 - TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS

Fig. 30 Valve Guide Height

1 - VALVE GUIDE
2 - 13.25 - 13.75 MM (0.521 - 0.541 IN.)
3 - SPRING SEAT

Fig. 31 Checking Bolts for Stretching (Necking)

1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT

Fig. 32 Cylinder Head Gasket Positioning

1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER

ENGINE 2.4L DOHC

9 - 105

CYLINDER HEAD (Continued)

NOTE: Head gaskets for Non-Turbo and Turbo appli-
cations are NOT interchangeable.

(1) Position the new cylinder head gasket on

engine block with the part number facing up (Fig.
32). 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 equiped engines tighten the

cylinder head bolts in the sequence shown in (Fig.
33). 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 equiped engines tighten the cylin-

der head bolts in the sequence shown in (Fig. 33).
Using the 4 step torque-turn method, tighten accord-
ing 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 9 -

ENGINE/CYLINDER

HEAD/CAMSHAFT(S)

INSTALLATION).

(7) Install cylinder head cover (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER - INSTALLATION).

(8) Install rear timing belt cover and timing belt

idler pulley (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - INSTALLATION).

(9) Install camshaft sprockets and timing belt

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT AND SPROCKETS - INSTALLATION).

(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

11 - EXHAUST SYSTEM/TURBOCHARGER SYS-
TEM/LINES AND HOSES - INSTALLATION) (Fig.
27).

• Install coolant return line

• Install coolant supply line

• Install oil supply line

• Install oil return tube
(14) Turbocharger equipped vehicles: (Fig. 26)
• Install elbow

• Install turbocharger support bracket

• Install elbow support bracket

• Install turbocharger heat shields
(15) Install exhaust pipe to manifold. Tighten fas-

teners to 28 N·m (20 ft. lbs.).

(16) Install accessory drive belts (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

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 (Fig. 25).

(21) Install fastener attaching dipstick tube to

lower intake manifold (Fig. 24) or (Fig. 25).

(22) Connect fuel supply line quick-connect at the

fuel rail assembly (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/QUICK CONNECT FITTING -
STANDARD PROCEDURE).

(23) Install upper intake manifold (Refer to 9 -

ENGINE/MANIFOLDS/INTAKE

MANIFOLD

INSTALLATION).

(24) Fill cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE).

(25) Connect negative cable to battery.
(26) Install clean air hose and air cleaner housing

(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER HOUSING - INSTALLATION).

Fig. 33 Cylinder Head Tightening Sequence

9 - 106

ENGINE 2.4L DOHC

CYLINDER HEAD (Continued)

CAMSHAFT OIL SEAL(S)

REMOVAL

(1) Remove timing belt (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).

(2) Hold each camshaft sprocket with Special Tool

6847 while removing center bolt (Fig. 34).

(3) Remove camshaft sprockets.
(4) Remove rear timing belt cover (Refer to 9 -

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

(5) Remove

camshaft

seal

using

Special

Tool

C-4679A (Fig. 35).

CAUTION: Do not nick shaft seal surface or seal
bore.

INSTALLATION

(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 (Fig.
36).

(3) Install timing belt rear cover (Refer to 9 -

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

(4) Install camshaft sprockets. Hold each sprocket

with Special Tool 6847 and tighten center bolt to 115
N·m (85 ft. lbs.) (Fig. 34).

(5) Install timing belt and front covers (Refer to 9 -

ENGINE/VALVE

TIMING/TIMING

BELT

AND

SPROCKETS

INSTALLATION)

(Refer

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

Fig. 34 Camshaft Sprocket - Removal/Installation

1 - SPECIAL TOOL 6847

Fig. 35 Camshaft Oil Seal - Removal With C-4679A

1 - SPECIAL TOOL C-4679

Fig. 36 Camshaft Seal - Installation

1 - SPECIAL TOOL MD-998306

ENGINE 2.4L DOHC

9 - 107

Content .. 704 705 706 707 ..