Chrysler PT Cruiser. Manual - part 691

STANDARD PROCEDURE

CYLINDER BORE HONING

(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 proce-
dure. 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 suf-
ficient 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 seat-
ing of rings (Fig. 56).

(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.

CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a

solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.

CLEANING

Clean cylinder block thoroughly using a suitable

cleaning solvent.

INSPECTION

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 9

- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).

(3) Examine block and cylinder bores for cracks or

fractures.

(4) Check block deck surfaces for flatness. Deck sur-

face 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 (Fig.
57) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.

Fig. 56 Cylinder Bore Cross-Hatch Pattern

1 - CROSS-HATCH PATTERN
2 - 40°–60°

Fig. 57 Checking Cylinder Bore Size

9 - 44

ENGINE 1.6L SOHC

ENGINE BLOCK (Continued)

Measure the cylinder bore at three levels in direc-

tions A and B (Fig. 57). 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 9 - ENGINE - SPECIFICATIONS).

CRANKSHAFT MAIN
BEARINGS

DESCRIPTION

NOTE: The upper and lower main bearing shells are
NOT interchangeable.

The crankshaft is supported by five main bearings.

All upper bearing shells in the crankcase have oil
grooves/oil

feed

holes. All

lower

bearing

shells

installed in the (bed plate) main bearing cap are
plain. Crankshaft end play is controlled by a flanged
bearing on the number three upper main bearing
journal (Fig. 58).

CRANKSHAFT

DESCRIPTION

The crankshaft is made of nodular cast iron and

includes five main bearing journals and four connect-
ing rod journals (Fig. 59). The number three journal
is the location for the thrust bearing. The crankshaft
utilizes a replaceable tonewheel for crankshaft posi-
tion sensor function.

STANDARD PROCEDURE - CRANKSHAFT END
PLAY

(1) Mount a dial indicator to front of engine, locat-

ing probe on nose of the crankshaft (Fig. 60).

(2) Move crankshaft all the way to the rear of its

travel.

(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front of its

travel and read the dial indicator. For crankshaft
specifications (Refer to 9 - ENGINE - SPECIFICA-
TIONS).

REMOVAL

(1) Remove engine assembly from vehicle (Refer to

9 - ENGINE - REMOVAL).

(2) Separate transaxle from engine.
(3) Remove clutch and pressure plate. Remove fly-

wheel.

(4) Remove crankshaft rear oil seal (Refer to 9 -

ENGINE/ENGINE

BLOCK/CRANKSHAFT

OIL

SEAL - REAR - REMOVAL).

(5) Mount engine on a suitable repair stand.

Fig. 58 Crankshaft Main Bearings

1 - UPPER CRANKSHAFT MAIN BEARINGS
2 - THRUST BEARING
3 - LOWER CRANKSHAFT MAIN BEARINGS

Fig. 59 Crankshaft

1 - CRANKSHAFT
2 - TONEWHEEL

Fig. 60 Checking Crankshaft End Play - Typical

ENGINE 1.6L SOHC

9 - 45

ENGINE BLOCK (Continued)

(6) Remove the right engine mount bracket (Refer

ENGINE/ENGINE

MOUNTING/ENGINE

MOUNT BRACKET - REMOVAL).

(7) Remove crankshaft vibration damper (Refer to

ENGINE/ENGINE

BLOCK/VIBRATION

DAMPER - REMOVAL).

(8) Remove

the

timing

chain

(Refer

ENGINE/VALVE

TIMING/TIMING

BELT/CHAIN

AND SPROCKETS - REMOVAL).

(9) Remove the intake manifold (Refer to 9 -

ENGINE/MANIFOLDS/INTAKE

MANIFOLD

REMOVAL).

(10) Remove the oil dipstick tube.
(11) Remove oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - REMOVAL).

(12) Remove oil pump pick-up tube (Fig. 61).

(13) Remove crankshaft position sensor.
(14) Using a permanent ink or paint marker, iden-

tify cylinder number on each connecting rod cap.

CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.

(15) Remove all connecting rod bolts and caps.

Care should be taken not to damage the fracture rod
and cap surfaces.

NOTE: Do not reuse connecting rod bolts.

(16)

Remove all main bearing cap and bed plate

bolts from the engine block (Fig. 55).

(17) Using a mallet tap the bed plate loose from

the engine block dowel pins.

CAUTION: Do not pry up on one side of the bed
plate. Damage may occur to cylinder block and bed
plate alignment.

(18) Bed plate should be removed evenly from the

cylinder block dowel pins.

(19) Lift out crankshaft from cylinder block. Be

sure not to damage the main bearings or journals
when removing the crankshaft.

INSPECTION

The crankshaft journals should be checked for

excessive wear, taper and scoring (Fig. 62). 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.

CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.

The upper number three bearing half is flanged to

carry the crankshaft thrust load and is NOT inter-
changeable with any other bearing halves in the
engine (Fig. 63). All bearing cap bolts removed dur-
ing service procedures are to be cleaned and oiled
before installation.

Fig. 61 Oil Pump Pick-up Tube

1 - FASTENERS
2 - OIL PUMP PICK-UP
3 - O-RING

Fig. 62 Crankshaft Journal Measurements - Typical

9 - 46

ENGINE 1.6L SOHC

CRANKSHAFT (Continued)

INSTALLATION

(1) Install the upper main bearing shells with the

lubrication groove in the cylinder block. (Fig. 63).

(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.

(3) Oil the bearings and journals and install

crankshaft in cylinder block.

CAUTION: Use only the specified anaerobic sealer
on the bed plate or damage may occur to the
engine.

(4) Apply 1.5–2.0 mm (0.059–0.078 in.) bead of

Mopar

t Bed Plate Sealant to bed plate as shown in

(Fig. 64).

(5) Install lower main bearings into main bearing

cap/bed plate. Make certain the bearing tabs are
seated into the bed plate slots. Install the main bear-
ing/bed plate onto engine block.

(6) Before installing the main bearing cap/bed

plate bolts, oil threads with clean engine oil, wipe off
any excess oil.

(7) Install and finger tighten the main bearing cap

bolts.

(8) Install and finger tighten the bed plate bolts.
(9) Snug the three bed plate bolts at the dowel

locations (bolts 11, 17, and 20) to bring the bed plate
down to the block (Fig. 65).

(10) Snug the remaining main bearing cap/bed

plate bolts.

(11) Torque the main bearing cap /bed plate bolts

to the sequence shown in (Fig. 65) to the following
torque:

• Main Bearing Cap Bolts — 61 N·m (45 ft. lbs.)

• Bed plate Bolts — 30 N·m (22 ft. lbs.)
(12) After the main bearing bed plate is installed,

check the crankshaft turning torque. The turning
torque should not exceed 5.6 N·m (50 in. lbs.).

(13) Check crankshaft end play (Refer to 9 -

ENGINE - SPECIFICATIONS).

(14) Install connecting rod bearings and caps.

Install new connecting rod bolts and tighten to 26
N·m (19 ft. lbs.) plus 1/4 turn.

(15) Install oil pick-up tube (Fig. 61).
(16) Install the oil pan (Refer to 9 - ENGINE/LU-

BRICATION/OIL PAN - INSTALLATION).

Fig. 63 Crankshaft Main Bearings

1 - UPPER CRANKSHAFT MAIN BEARINGS
2 - THRUST BEARING
3 - LOWER CRANKSHAFT MAIN BEARINGS

Fig. 64 Bed plate Sealing

Fig. 65 Main Bearing Caps/Bed plate Torque

Sequence

ENGINE 1.6L SOHC

9 - 47

CRANKSHAFT (Continued)

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