PT Cruiser, 2001 - 2005

Cylinder Head

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Removal & Installation




NOTE
After all components are installed on the engine, a DRB® scam tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner inlet duct and air cleaner
     
    Inlet Air Temperature (IAT) sensor and make-up air hose
     
    Upper intake manifold
     
    Dipstick tube fastener
     
    Lower intake manifold support bracket on turbo models
     
    Fuel supply line from the fuel rail
     
    Heater tube support bracket
     
    Upper radiator hose
     
    Heater supply hoses
     
    Accessory drive belt
     
    Exhaust pipe from the manifold
     

  8.  
  9. On turbo models perform the following:
    1. Remove the turbocharger heat shields.
    2.  
    3. Remove the elbow support bracket.
    4.  
    5. Remove the turbocharger support bracket.
    6.  
    7. Remove the oil return, oil supply, coolant return and coolant supply hoses.
    8.  

  10.  
  11. Remove or disconnect the following:
    NOTE
    The cylinder head bolts must be inspected before they can be reused. If the threads of bolts are stretched, they must be replaced. Check for thread stretching by holding a scale or other straightedge against the threads. If all the threads do not contact the scale, the bolts must be replaced.


    WARNING
    Use only a plastic scraper to clean the mating surfaces. NEVER use metal, as this may gouge the surfaces and cause leaks.



    Power steering pump, move it aside. DO NOT disconnect the fluid lines.
     
    Ignition coil pack wiring connector
     
    Ignition coil pack and bracket
     
    Cam sensor electrical connector
     
    Timing belt
     
    Timing belt idler pulley
     
    Camshaft sprocket
     
    Power steering pump reservoir and bracket, if necessary on Non-Turbo models
     
    Cylinder head cover
     
    Camshaft and cam followers
     
    Cylinder head bolts, working from the center outward
     
    Cylinder head
     

  12.  
  13. Cover the combustion chambers, then use a plastic scraper to thoroughly and carefully clean the engine block and cylinder head mating surfaces.
  14.  

To install:

Click image to see an enlarged view

Fig. Install the new gasket with the part number facing upwards

  1. Install the cylinder head with a new gasket. Make certain that the part number on the new gasket is facing up.
  2.  
  3. Lubricate the cylinder head bolt threads with clean engine oil.
  4.  
  5. Torque the cylinder head bolts, in the following sequence:
    1. Step 1: 25 ft. lbs. (34 Nm).
    2.  
    3. Step 2: 50 ft. lbs. (68 Nm).
    4.  
    5. Step 3: 50 ft. lbs. (68 Nm).
    6.  
    7. Step 4: An additional 1 / 4 turn.

      Click image to see an enlarged view

      Fig. Cylinder head bolt torque sequence

    8.  

  6.  
  7. Install or connect the following:

    Camshaft and cam follower assemblies
     
    Cylinder head cover
     
    Rear timing belt cover and pulley
     
    Camshaft sprockets
     
    Timing belt
     
    Cam sensor wiring connector
     
    Ignition coil and spark plug wires
     
    Power steering pump reservoir and bracket, if removed
     

  8.  
  9. On turbo models perform the following:
    1. Install the oil return, oil supply, coolant return and coolant supply hoses.
    2.  
    3. Install the elbow support bracket.
    4.  
    5. Install the turbocharger heat shields.
    6.  
    7. Install the turbocharger support bracket.
    8.  

  10.  
  11. Install or connect the following:

    Exhaust pipe to the manifold
     
    Accessory drive belts
     
    Lower intake manifold
     
    Upper radiator and heater supply hose
     
    Heater support bracket
     
    Lower intake manifold support bracket on turbo models
     
    Dipstick tube fastener
     
    Power brake vacuum hose to the intake manifold
     
    Fuel supply line to the fuel rail
     
    Vacuum lines and electrical wiring
     
    Upper intake manifold
     
    Air cleaner inlet duct and air cleaner
     
    IAT sensor and make up hose
     
    Negative battery cable
     

  12.  
  13. Fill the cooling system.
  14.  
  15. Turn the ignition switch ON , and access the -miscellaneous- screen.
  16.  
  17. Select the -re-learn cam/crank- option, then follow the instructions on the scan tool screen.
  18.  

 
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