VALVE COVER GASKET REMOVAL GUIDE

Chrysler PT Cruiser, 2001 - 2005 Valve Cover Gasket Removal details and procedure:-------

Also valve cover gasket removal for other car model is listed below:---

The very common problem noticed is oil fouling.

The oil fouling is most likely a result of the valve cover gasket leaking down in one or more of the spark plug towers ,on the cover gasket there are 4 gaskets which stop the oil from leaking into the spark plug sockets,these get brittle and dont seal .


The details that will help you while doing this Valve Cover Gasket replacing Job


The valve cover gasket comes with spark plug seals.
You have to remove the intake manifold, accelerator linkage, and some other electrical and vacuum connections.

In this process without forget to replace the PCV while your doing this..... This is because  with the Turbo (after 100K miles) that clean air and gas are a must.

Its not a difficult job.
The replacement takes approx 3 hours.
I hope this helps some others experiencing this problem...


Please note while doing this job.

The Torque specs.

Max torque  105 in lbs and that is equal to 8.75 ft lbs.

105 in-lbs, 12Nm.
BUT they are supposed to be torqued down in increments. First 40 in-lbs, then 80 in-lbs then up to the 105 in-lbs.
VALVE COVER GASKET REMOVAL DETAILS STARTS HERE:----------

Removal & Installation

1. Remove upper intake manifold.
2. Remove ignition coil and spark plug wires.
3. Disconnect PCV and make-up air hoses from cylinder head cover.
4. Remove cylinder head cover bolts.
   
   WARNING

   When removing cylinder head cover bolts, be careful not to interchange the center bolts with the seven perimeter bolts. The two center bolts contain an aluminum washer between the bolt head and torque limiter for sealing purposes.
5. Remove cylinder head cover from cylinder head.

To install:

NOTE

Replace spark plug well seals and bolt seals when installing a new cylinder head cover gasket.

1. Install new cylinder head cover gaskets and spark plug well seals.
2. Replace cylinder head cover bolt seals.
   
   CAUTION

   Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping.
3. Apply Mopar® Engine RTV GEN II at the camshaft cap corners and at the top edges of the 1/2 round seal.
   
   CAUTION

   When installing cylinder head cover bolts, be careful not to interchange the two center bolts with the seven perimeter bolts. The two center bolts contain an aluminum washer between the bolt head and torque limiter for sealing purposes.
4. Install cylinder head cover assembly to cylinder head. Install all bolts, ensuring the two bolts containing the sealing washer are located in the center locations of cover.
5. Tighten bolts in sequence shown in. Using a 3 step torque method as follows:
   
   
   Tighten all bolts to 40 inch lbs. (4.5 Nm)

   Tighten all bolts to 80 inch lbs. (9.0 Nm)

   Tighten all bolts to 105 inch lbs. (12 Nm)
6. Install ignition coil and spark plug wires. Tighten fasteners to 105 inch lbs. (12 Nm).
7. If the PCV valve was removed, apply Mopar® Thread Sealant with Teflon to threads and install valve to cylinder head cover. Tighten PCV valve to 70 inch lbs. (8 Nm).
8. Connect PCV and make-up air hoses to cylinder head cover.
9. Install upper intake manifold.

ALSO FOLLOW THIS OTHER PARTS REMOVAL INSTALLATION PROCEDURE.THIS WILL BE REQUIRED TO REPLACE VALVE COVER GASKET:-----

You have remove the entire Upper Intake Manifold and have full access to the Valve Cover:

• First Disconnect throttle support (It has 2 nuts), disconnect throttle cables,
• Disconnect electrical connectors and hose connections.There are four (4) electrical connectors and four (4) hose connections.
• once this is done remove Ignition Coil Pack.There are four(4) bolts attached to top of valve cover
• Now Disconnect Spark Plug wires from Spark Plugs
• After that you have to Disconnect Steering Fluid reservoir.For that there are  two (2) bolts.Remove the bolt and tie it to the side and out of the way.
• Now major task comes to end the last you have to Remove nine (9) valve cover bolts and they stay in cover if yo don't pull them out.

Upper Intake Manifold (Plenum)

PLEASE NOTE PROCEDURE IS DIFFERENT FOR TURBO AND NON-TURBO MODELS

Procedure for both are provided below:----

Removal & Installation

Non-Turbo Models

1. Before servicing the vehicle, refer to the Precautions section.
2. Properly relieve the fuel system pressure.
3. Remove or disconnect the following:
   
   
   Negative battery cable

   Inlet Air Temperature (IAT) sensor and air hose

   Engine cover

   Throttle and cruise control cables from the throttle lever bracket

   Manifold Absolute Pressure (MAP) sensor

   Idle Air Control (IAC) motor electrical connector

   Throttle Position (TPS) sensor wiring connector

   Proportional purge hoses

   Brake booster vacuum hose

   Positive Crankcase Ventilation (PCV) hose from the intake manifold

   Throttle body support bracket bolt

   Exhaust Gas Recirculation (EGR) tube from the upper intake manifold

   Upper intake manifold
4. Clean the mating surfaces. 
   
   
   
   Fig. Remove the EGR tube from the upper intake manifold

To install:

Fig. Upper intake manifold bolt torque sequence-Non-Turbo models

1. Install or connect the following:
   
   
   New gaskets and seals

   Intake manifold on the EGR tube then on the lower intake manifold. Torque the bolts, in sequence, to 20 ft. lbs. (28 Nm) on 2002 models or 105 inch lbs. (12 Nm) on 2003-06 models.

   Throttle body support bracket and torque the bolt to 28 ft. lbs. (20 Nm)

   EGR retainer plate and torque the smaller bolt to 95 inch lbs. (11 Nm) and the large bolt to 28 ft. lbs. (21 Nm)

   PCV hose to the intake manifold

   MAP sensor electrical connector

   Proportional purge hoses

   Brake booster hose

   IAC motor and TPS connectors

   Throttle and speed control cables

   Air cleaner assembly

   Engine cover

   IAT sensor

   Negative battery cable

Turbo Models

NOTE

The engines in these vehicles are equipped with either an aluminum or plastic manifold.

1. Before servicing the vehicle, refer to the Precautions section.
2. Properly relieve the fuel system pressure.
3. Remove or disconnect the following:
   
   NOTE

   Cover the lower intake manifold to avoid dirt and other objects from entering.
   
   
   
   
   Negative battery cable

   Inlet Air Temperature (IAT) sensor

   Manifold Absolute Pressure (MAP) sensor

   Throttle inlet pressure hose

   Charge air cooler hose from the throttle body

   Idle Air Control (IAC) motor electrical connector

   Throttle control shield

   Throttle and cruise control cables from the throttle lever bracket

   Throttle cable bracket

   Brake booster vacuum hose

   Positive Crankcase Ventilation (PCV) hose from the intake manifold

   Purge solenoid hose from the throttle body

   Upper intake manifold support bracket and manifold
4. Clean the mating surfaces.

To install:

Fig. Upper intake manifold bolt torque sequence-turbo models

1. Remove the cover from the lower intake manifold.
2. Install or connect the following:
   
   
   New gasket

   Intake manifold on the lower intake manifold. If equipped with an aluminum manifold, torque the bolts in sequence to 250 inch lbs. (28 Nm). If equipped with a plastic manifold, torque the bolts in sequence to 105 inch lbs. (12 Nm).

   Upper intake manifold support bracket Torque the retainers to 250 inch lbs. (28 Nm).

   Purge solenoid hose to the throttle body

   Brake booster vacuum hose

   PCV hose

   Throttle cable bracket and tighten the screws to 105 inch lbs. (12 Nm)

   Throttle and cruise control cables to the throttle lever bracket

   Throttle control shield

   IAC motor electrical connector

   MAP sensor

   Charge air cooler hose to the throttle body

   IAT sensor

   Throttle inlet pressure hose

   Negative battery cable

This details will help.

Thanks.

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