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TIMING BELT Removal 1. Disconnect negative battery cable. Remove upper engine torque strut attaching bolts and remove engine torque strut. See Fig. 5 . Remove engine torque strut bracket from strut tower. On PT Cruiser (Turbo), discharge and evacuate A/C system. Disconnect A/C lines at junction block near upper timing belt cover. 2. On all models, remove upper timing belt cover bolts and remove cover. See Fig. 6 . Raise vehicle on hoist and remove right front wheel. Remove splash shield. See Fig. 7 . Remove accessory drive belts. Remove crankshaft damper. See Fig. 8 . Remove pencil strut. See Fig. 2 . Remove lower engine torque strut. See Fig. 5 . 3. Disconnect exhaust system front pipe from manifold. Disconnect A/C pressure switch at rear of compressor housing. Lower vehicle and support engine with a jack. If not done previously, discharge and evacuate A/C system. Disconnect A/C lines at junction block. Remove screw attaching ground strap to strut bracket. Remove torque strut bracket from strut tower. Remove upper radiator closure panel. Without disconnecting lines from power steering pump, remove pump and bracket and set pump aside. 4. With engine properly supported, remove right engine mount through-bolt. See Fig. 5 . Raise engine with jack until engine support bracket bolts are accessible, and remove engine support bracket. See Fig. 9 . Remove lower timing belt cover bolts and remove cover. See Fig. 6 . CAUTION: When aligning crankshaft and camshaft timing marks, always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed, or damage to valve components may occur. CAUTION: Crankshaft sprocket TDC mark is located on the trailing edge of sprocket tooth. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause camshaft timing marks to be misaligned. 5. Before removal of timing belt, rotate crankshaft until TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth). See Fig. 10 . 6. Loosen timing belt tensioner lock bolt, and insert a 6-mm Allen wrench into hexagon opening located on top plate of belt tensioner pulley. See Fig. 11 . Rotate top plate clockwise until there is enough slack in timing belt to allow for removal. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. CAUTION: If timing belt was damaged due to incorrect rotating tracking (alignment), belt tensioner pulley and bracket must be replaced as an assembly.

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1. Install cylinder head. A. Place cylinder head on cylinder block. (a) Place a new cylinder head gasket on the cylinder block. CAUTION: Be careful of the installation direction. (b) Place the cylinder head on the cylinder head gasket. B. Install cylinder head bolts. NOTE: The cylinder head bolts are tightened in 2 progressive steps (steps (b) and (d)). If any cylinder head bolt is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Cylinder Head Installation Install and uniformly tighten the 10 cylinder head bolts and plate washers in several passes, in the sequence shown. Torque: 49 Nm (36 ft. lbs.) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. (c) Mark the front of the cylinder head bolt head with paint. (d) Retighten the cylinder head bolts 90° in the numerical order shown. (e) Check that the painted mark is now at a 90° angle to the front. Install the 2 bolts holding the water bypass pipe to the cylinder head. Torque to 19 Nm (14 ft. lbs.) (g) Connect the camshaft position sensor connector. 2. Install spark plug tubes. (a) Clean the cylinder head tube holes of any residual adhesive, oil or foreign particles. Remove any oil with kerosene or gasoline. (b) Screw the threads of the spark plug tube coated with adhesive into the cylinder head.

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Fig. 82: Removing/Installing Cylinder Head Gasket REMOVAL SERVICE POINT << A >> CYLINDER HEAD ASSEMBLY REMOVAL Use special tool MD998051 to loosen each bolt two or three steps in the order shown in the illustration. Fig. 83: Removing Cylinder Head Fig. 84: Identifying Cylinder Head Gasket On Cylinder Block With Identification Mark At Front Top INSTALLATION SERVICE POINTS >>A<< CYLINDER HEAD GASKET INSTALLATION 1. Degrease the cylinder head and cylinder block gasket mounting surfaces. 2. Make sure that the gasket has the proper identification mark for the engine.

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All vehicles 1. Remove the valve cover. For additional information, refer to Section 303-01C. 2. Disconnect the fuel injector electrical connector. Two-piece head tube 3. NOTE: Some engines may have been updated with a new two-piece crankcase-to-head tube. If the crankcase-to-head tube has been updated it will have a hex head. If the high-pressure oil rail has a hex head, remove the crankcase-to-head tube assembly. Remove and discard the O-ring seals. All vehicles 4. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components. NOTE: Use a tool like the KD Tool #58965 or Lisle T30 to avoid interference with the evaporator case. Remove the bolts and the high-pressure oil rail. One-piece head tube 5. NOTE: The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly. Remove the crankcase-to-head tube. Remove and discard the O-ring seal. Two-piece head tube 6. CAUTION: Use care not to deform the lower crankcase-to-head tube during removal. If the tube is damaged, a new tube must be installed. NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing. If the updated crankcase-to-head tube separated, using a pair of soft jawed pliers, remove the lower crankcase-to-head tube. All vehicles 7. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier. 8. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug. 9. CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system, causing severe engine damage. CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole. NOTE: There is no need to drain the fuel rail. NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve. For additional information, refer to Fuel Injector Sleeve in this section. NOTE: Use a tool like Snap-On SDMT440 torx to avoid damaging the fuel injector plastic and to avoid interference with the evaporator case. Remove the bolt, fuel injector hold-down clamp and fuel injector. Installation One-piece head tube

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Cylinder Head Special Tool(s) Compressor, Valve Spring 303-567 (T97P-6565-AH) Spacer, Valve Spring Compressor 303-382 (T91P-6565-AH) Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A) Material Metal Surface Cleaner F4AZ-19A536-RA Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP Disassembly All engines 1. On Windsor engines, remove the Camshaft Position Aligner from the camshaft (6250). Item Specification WSE-M5B392-A WSS-M2C153-H 2. CAUTION: Do not remove the camshaft before removing the roller followers. CAUTION: Place the cylinder head (6049) on a cardboard or wood surface to prevent damage to the joint face. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage. 3. NOTE: The roller followers must be reinstalled in their original locations. Record roller follower locations. Use the Valve Spring Compressor to compress the valve springs (6513), and remove the roller followers. 4. NOTE: The hydraulic lash adjusters must be installed in their original locations. Record hydraulic lash adjuster locations. Remove the hydraulic lash adjusters. 5. NOTE: Windsor engine shown; Romeo engine is similar. Use the Valve Spring Compressor to compress the valve springs. 6. CAUTION: Keep the valves and valve spring retainer keys (6518) in order so they can be installed in the same positions. NOTE: Shown without camshaft for clarity. Remove the (A) valve spring retainer keys, the (B) valve spring retainers (6514), the (C) valve springs, and the valves. 7. Remove the valve stem seals (6571). Romeo engine (4.6L) 8. NOTE: The camshaft bearing caps must be installed in their original location. Record camshaft bearing cap location. Remove the bolts, the bearing caps and the camshaft. Windsor engine (5.4L) Assembly All engines 1. CAUTION: Do not use metal scrapers or other tools to clean the cylinder head or damage to the head can occur. Use a plastic scraper and metal surface cleaner to clean the cylinder head. 2. Lubricate the camshaft journals with clean engine oil.