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`vnlhl V" :7
`
`AUTO REPAIR MANUAL
`1993-97
`
`Publisher & Editor-ln-Chief
`Executive Editors
`Managing Editor
`Senior Editors
`
`'
`
`Project Managers
`
`Editorial Staff
`
`Production Manager
`Assistant Production Manager
`Production Specialists
`
`Director of Manufacturing
`Manufacturing Manager
`OFFICERS
`Senior Vice President
`
`Kerry A. Freeman, S.A.E.
`Dean F. Morgantini, S.A.E., W. Calvin Settle Jr., S.A.E.
`Nick D’Andrea
`Jacques Gordon, Michael L. Grady, Kevin M. G. Maher, Debra
`McCall, Richard J. Rivele, S.A.E., Richard T. Smith, Jim Taylor,
`Ron Webb
`Larry Braun, S.A.E., A.S.C., Thomas P. Browne Ill, Joseph L.
`DeFrancesco,‘A.S.E., Robert E. Doughten, Ben Greisler, S.A.E.,
`Martin J. Gunther, Craig P. Nangle, A.S.E., S.A.E., Ernest H.
`Ralph, A.S.E., S.A.E., Richard Schwartz
`Jaffer A. Ahmad, Robert Chabot, William Cottman, A.S.E.,
`Leonard Davis, A.S.E., Michael DiFurio Jr., S.A.E., Sam Fiorani,
`Matthew E. Frederick, William C. Friedauer, Edward Giacomucci,
`A.S.E., S.A.E., AI Gibbs, Herbert Guie Jr, George B. Heinrich Ill,
`Dawn M. Hoch, Daniel Howells, A.S.E., David E. Jester, A.S.E.,
`Lori L. Johnson, A.S.E., Will Kessler, A.S.E., Kenneth F.
`Konzelman, Neil J. Leonard, A.S.E., James R. Marotta, Robert
`McAnally, Thomas A. Mellon, Raymond K. Moore, A.S.E., Norman
`D. Norville, A.S.E., Christine L.- Nuckowski, Eric 8. Peterson,
`A.S.E., Charles Ramsey,,A.S.E., William L. Renn, A.S.E., Roy
`Ripple, A.S.E., George E. Ritter, Robert Saxton, A.S.E., S.A.E.,
`Paul Shanahan, Larry E. Stiles, Gordon L. Tobias, S.A.E., Albert
`A. Wood, A.S.E.
`Andrea M. Steiger
`Marsha Park-Herman
`Christina Davis, Kimberly T. Hayes, Joseph C. McGinty, Liz
`Thompson
`Mike D’Imperio
`Robin Norman
`
`‘
`
`Ronald A. Hoxter
`
`nun! rang-329:3
`vn'L' VIICOMPANY
`ONE OF THE DIVERSIFIED PUBLISHING COMPANIES,
`A PART OF CAPITAL ClTIES/ABC,INC.
`Manufactured in
`
`© 1996 Chilton Book Company
`Chilton Way, Radnor, PA 19089
`ISBN 0-8019-7919-6
`ISSN
`
`000001
`
`JCI 1016
`
`

`

`4 CHRYSLER CORP. SEBRING/AVENGER
`
`
`
`
`56 Nm‘ m
`41 ft.|bs.‘
`
`1. Rear roll stopper bracket assembly
`2. Front roll stopper bracket assembly
`El Replace with a new nut
`
`.-Caution
`
`:
`
`Indicates parts which should be temporarily tightened,
`and then tully tightened with the vehicle on the ground
`in the unladen condition.
`
`292959
`
`Front and rear engine roll stoppers
`
`2. Using a 7137 or a 0-4852 en-
`gine lift or equivalent, raise and
`safely support the'engine so it is not
`resting on the engine mounts. Use
`care not to bend or damage any
`components.
`3. Remove the stopper through
`
`4. Remove the stopper mount
`frame bolts and pry the mount out.
`To install
`\
`5. Position the lower front roll
`stopper and install the frame mount—
`ing bolts and tighten to 32 ft. lbs. (44
`
`6. Install the through bolt, but do
`not fully tighten until the full weight
`of the engine is on the mount. Torque
`the nut to 41 ft. lbs. (56 Nm).
`7. Connect the negative battery
`
`2.5L(VIN N) Engine
`
`Upper Mount
`
`1. Disconnect the negative battery
`cable. Remove the air cleaner and all
`necessary air duct work.
`2. Using a MB991453 and
`MZ203827 engine lifting assembly or
`equivalent, raise and safely support
`the engine so it is not resting on the
`engine mounts.
`3. Remove the engine mount
`
`bolt. Take note of the position of the
`arrow on the oval shaped mounting
`stopper plate. This is important for
`reinstallation purposes.
`4. Remove the engine mounting
`bracket and stopper plate.
`To install:
`the engine mounting
`5. Install
`bracket and stopper plate. Note the
`arrows on the stopper plates and
`make sure they are installed prop-
`erly. On most engines the arrows will
`face towards the center of the engine.
`Torque the upper mount to engine
`nut and bolt to 63 ft. lbs. (86 Nm) and
`the upper mount through bolt nut to
`71—85 ft. lbs. (98—118 Nm).
`6. Install the air cleaner and all
`air duct work previously removed.
`7. Connect the negative battery
`cable.
`
`Engine Roll Stopper (Lower Rear Mount)
`1. Disconnect the negative battery
`cable.
`'
`
`2. Using a MB991453 and
`MZ203827 engine lifting assembly or
`equivalent, raise and safely support
`the engine so it is not resting on the
`engine mounts. Use care not to bend
`or damage any components.
`3. Remove the stopper through
`
`To install
`5. Position the lower rear roll stop—
`per so the part of the bracket With
`the hole in it is facing the front of the
`vehicle.
`Install the frame mounting
`bolts and tighten to 32 ft.
`lbs. (44
`Nm).
`6. Install the through bolt and tor-
`que the nut to 32 ft. lbs. (44 Nm).
`7. Connect the negative battery
`cable.
`
`Engine Roll Stopper (Lower Front Mount)
`1. Disconnect the negative battery
`cable.
`
`2. Using a MB991453 and
`MZ203827 engine lifting assembly or
`equivalent, raise and safely support
`the engine so it is not resting on the
`engine mounts. Use care not to bend
`or damage any components.
`3. Remove the stopper through
`
`4. Remove the stopper mount
`frame bolts and pry the mount out.
`To install
`5. Position the lower front roll
`stopper and install the frame mount-
`ing bolts and tighten to 32 ft. lbs. (44
`Nm).
`6. Install the through bolt, but do
`not fully tighten until the full Weight
`of the engine is on the mount. Torque
`the nut to 41 ft. lbs. (56 Nm).
`7. Connect the negative battery
`cable.
`
`Cylinder Head
`
`REMOVAL AND INSTALLATION
`
`2.0L(VIN Y) Engine
`
`CAUTION .
`Fuel injection systems remain
`under pressure, even after the en-
`gine has been turned OFF. The
`fuel system pressure must be re-
`lieved before disconnecting any
`fuel lines. Failure to do so may re-
`sult
`in fire and/or personal
`injury.x
`
`1. Following proper procedure, re-
`lieve the fuel system pressure.
`2. Disconnect the negative battery
`cable.
`
`3. Remove the air cleaner with all
`air intake hoses.
`4. Drain the cooling system and
`the engine oil.
`5. Disconnect
`cable.
`
`the accelerator
`
`6. Disconnect the small vacuum
`hose at the pressure regulator;
`7. Disconnect the oxygen sensor,
`
`000002
`
`JCI 1016
`
`

`

`SEBRING/AVENGER CHRYSLER CORP. 4
`
`N I
`
`Stretched
`
`x;
`Unstretched bolt
`
`l
`
`
`I
`Threads are not straight on line
`Threads are straight on line
`illllllllllllllllllllllllllllllllllllllll
`
`.
`297118
`
`Checking the cylinder head bolts for necking
`(stretching) — 2.0L engine
`
`
`
`'Locaiion ol110 mm (4.330 in.) short bolts.
`297119
`
`Cylinder head torque sequence —_2.0L engine
`
`gauge unit and the engine coolant
`temperature switch on vehicles with
`air conditioning.
`8. Disconnect the throttle position
`sensor, crankshaft angle sensor, fuel
`injectors,
`ignition coil pack, EGR
`temperature sensor, ground cable
`and engine control wiring harness.
`9. Remove the spark plug cable
`center cover and remove the spark
`plug cables.
`'
`10. Disconnect and plug the high
`pressure fuel line.
`11. Remove the heater hose and the
`water hose connections.
`12. Remove the PCV hose.
`13. Disconnect and plug the fuel re—
`turn hose.
`14. Disconnect the brake booster
`vacuum hose.
`15. Remove the timing belt.
`16. Remove the valve cover and the
`half-round seal.
`17.. Remove the exhaust pipe self-
`lockmg nuts and separate the ex-
`haust pipe from the exhaust mani—
`fold. Discard the gasket.
`18. Remove the intake and exhaust
`camshafts.
`19. Loosen the cylinder head
`mounting bolts and lift off the cylin—
`
`20. Place the assembly on a suita-
`ble workbench and remove the intake
`and exhaust manifolds.
`» 21. Remove the head gasket.
`To install:
`
`22. Thoroughly clean and dry the
`mating surfaces of the head. and
`block. Check the cylinder head for
`cracks, damage or engine coolant
`leakage. Remove scale, sealing com-
`pound and carbon. Clean the oil
`passages thoroughly. Check the head
`for flatness. End to end, the head
`should be no more than 0.004 inch
`(0.1 mm) out—of—true.
`23. Place a new head gasket on the
`cylinder block with the identification
`marks at the front top (upward) posi—
`tion. Make sure the gasket has the
`proper identification mark for the en-
`gine. Do not use sealer on the gasket.
`24. New head bolts are recom-
`mended. Inspect the cylinder head
`bolts prior to installation. If the
`threads are necked down (stretched),
`the bolts should be replaced. Necking
`can be checked by holding a straight
`edge against the threads. If all the
`threads do not contact the straight-
`edge, the bolt should be replaced.
`25. Carefully install
`the cylinder
`head on the block. Before installing
`the bolts, the threads should be oiled
`with clean engine oil.
`26. Tighten the cylinder head bolts
`in sequence as follows:
`a. Tighten the center bolts (1
`through 6) to 25 ft. lbs. (33 Nm).
`Then tighten the outer bolts (7
`through 10) to 20 ft. lbs. (27 Nm).
`b. Tighten the center bolts (1
`through 6) to 50 ft. lbs. (67 Nm).
`Then tighten the outer bolts (7
`through 10) to 20 ft. lbs. (27 Nm).
`c. Tighten the center bolts (1
`through 6) to 50 ft. lbs. (67 Nm).
`Then tighten the outer bolts (7
`through 10) to 20 ft. lbs. (27 Nm).
`d. Tighten all 10 bolts an addi-
`tional 1/4 turn (90 degrees).
`27. Install the new exhaust pipe
`gasket and connect the exhaust pipe
`to the manifold. Tighten the self—
`locking bolts to 33 ft. lbs. (44 Nm).
`28. Apply sealer to the perimeter of
`the half-round seal and to the lower
`edges of the half-round portions of
`the belt-side of the new gasket. In-
`stall the valve cover.
`29. Install the timing belt and all
`related items.
`
`30. Connect or install all previously
`disconnected hoses, cables and elec-
`trical connections. Adjust the throttle
`
`32. Replace the O-rings and connect
`the fuel lines.
`33. Install the air cleaner and in-
`take hose. Connect the breather hose.
`34. Change the engine oil and oil
`filter.
`
`35. Install the radiator and fill the
`system with coolant.
`36. Connect the negative battery
`cable, with the radiator cap off, run
`the vehicle until
`the thermostat
`opens checking the coolant level to
`fill the radiator completely.
`37. Once the vehicle has cooled,
`recheck the coolant level.
`
`2.5L(VIN N) Engine ’
`
`CAUTION
`Fuel injection systems remain
`under pressure, even after the en-
`gine has been turned OFF. The
`fitel system pressure must be re-
`lieved before disconnecting any
`fitel lines. Failure to do so may re-
`sult
`in fire and/or personal
`injury.a
`
`1. Safely discharge the residual
`pressure from the fuel system.
`2. Disconnect the negative battery
`cable.
`
`3. Drain the cooling system.
`4. Remove the air intake plenum.
`5. Disconnect the upper radiator
`hose from the thermostat housing.
`6. Identify and label and discon-
`nect the various connectors along the
`engine control harness. This should
`save time at assembly. Position the
`harness and wiring leads out of the
`way.
`
`7. Remove the intake manifold
`with the injectors and fuel rail
`attached.
`
`8. Label and disconnect the wiring
`to the spark plugs corresponding to
`the head being removed.
`9. Disconnect the oxygen sensor
`wiring.
`'
`10. Remove the self-locking nuts
`holding each (front and rear) exhaust
`pipe to the exhaust manifolds. Re-
`move the small bracket bolts and sep-
`arate the exhaust system from the
`engine.
`11. Remove the dipstick and tube
`from the engine block (front head
`only).
`-
`12. Remove the heat shield from
`the exhaust manifold and remove the
`manifold from the head.
`13. Remove the exhaust manifold
`gasket.
`14. Remove the bolt holding the
`
`000003
`
`JCI 1016
`
`

`

`6 DODGE/PLYMOUTH NEON
`
`
`
`
`
`‘
`'
`<Long bolts> ,
`33,Nm -—) 67 Nm —) 61 Nm —) +90"
`(25 Ribs. -)501t.lbs. —) 50 tubs. —) +90°)
`<Short bolts>
`.
`21 Nm—->27Nm—)27Nm—>+90°
`(20 ftlbs. —>20ft.lbs. —+ 20 (Libs. -) +93")
`
`
`
`1. Front emaust pipe
`connection
`2. Gasket
`
`3. Cylinder head bolt
`
`4. Cylinder head
`5. Q/linder head gasket
`
`III. Replace with new
`
`component
`
`
`
`44 Nm
`33 ttJbs.
`
`20-25 Nm
`14-13 flJbs.
`
`
`til
`
`
`
`297117
`
`Cylinder head exploded View -- 2.0L DOHC engine
`
`
`ill—tumultmmiuulmnmmlm
`I
`Threads are not straight on line
`
`Threads are straight on line.
`(CI-iiillllllllllllll‘llllill-lllllilllillllfl
`
`Unstretched bolt
`
`297118
`
`Checking the cylinder head bolts for necking
`
` /
`
`’Lccation of 110 mm (4.330 in.) short bolts.
`297119
`
`Cylinder head torque sequence — 2.0L DOHC
`
`26. Tighten the cylinder head bolts
`in sequence as follows:
`~
`a. Tighten the center bolts (1.,
`through 6) to 25 ft. lbs. (33 Nm).
`Then, tighten the outer bolts (7
`through 1.0) to 20 ft. lbs. (27 Nm).
`b. Tighten the center bolts (1
`through 6) to 50 ft. lbs. (67 Nm).
`Then, tighten the outer bolts (7
`through 10) to 20 ft. lbs. (27 Nm).
`0. Tighten all 10 bolts an addi
`tional 1/4 turn (90 degrees).
`'
`27. Install the new exhaust pipe
`gasket and'connect the exhaust pipe
`to the manifold..Tighten the self—lock—
`ing bolts to 33 ft. lbs. (44 Nm). ,
`28. Apply sealer to the perimeter of
`the half-round seal and to the lower
`edges of the half-round portions‘of
`the belt-side of the new gasket.
`In—
`stall the valve cover.
`29. Install the timingvbelt and all
`related items.
`
`30. Connect or install all previously
`disconnected hoses, cables and elec-
`trical connections. Adjust the throttle
`cable(s).
`31. Install the spark plug cable
`center cover.
`
`32. Replace the O-rings and connect
`the fuel lines.
`33. Install the air cleaner and in-
`take hose. Connect the breather hose.
`34. Change the engine oil and oil
`
`.
`
`35. Installthe radiator and fill the
`p
`system with coolant. '
`36. Connect the negative battery 4
`cable, with the radiator cap off, run
`the vehicle until the thermostat
`opens checkingthe coolant level to
`fill the radiator completely.-
`_
`37. Once the vehicle has cooled,
`recheck the coolant level.
`-
`
`2.0L (VIN C) SOHO Engine
`This engine uses a Single Over Head
`Camshaft (SOHC) 4-valves per cylin-
`der cross flow aluminum cylinder
`head. Care must be taken to make
`sure all valve timing marks align af-
`ter cylinder head service.
`
`CAUTION— '
`Fuel injectionsystems remain
`under pressure, even afl‘er the en-
`gine has been turned OFF. The
`fuel system pressure must be re-
`lieved before disconnecting any
`fuel lines. Failure to do so may re-
`sult
`in fire and/or personal
`injury.
`
`1. Disconnect the negative battery
`cable remoteyconnection located on
`the left strut tower.
`'
`2. Relieve the fuel system pres-
`sure using the-recommended
`procedure.
`.
`3. Remove the air cleaner.
`4. Drain and properly contain the
`engine coolant.
`'
`5. Disconnect and tag all vacuum
`hoses and all electrical connections
`from the throttle body.
`6. Remove the throttle linkage.
`7. Remove the accessory drive
`be1t(s).
`the power brake
`8. Disconnect
`booster vacuum hose.
`9. Raise and safely support the
`vehicle.
`-
`10. Disconnect
`the exhaust pipe
`from the exhaust manifold.
`11. Remove the power steering
`pump and move aside.
`12. Remove the coil pack and
`bracket from the engine.
`13. Disconnect the cam sensor and
`fuel injector wiring.
`14. Remove the timing belt the rec—.
`ommended procedure.
`15. Remove the valve cover.
`16. Remove the rocker arm shafts.
`17. Remove the cylinder head bolts
`and remove the cylinder head.
`To install:
`
`'
`
`NOTE: The cylinder head bolts
`should be checked for stretching ‘
`before reuse. If the thread area of
`the bolt is neCked down the bolts
`
`000004
`
`JCI 1016
`
`

`

`NEON DODGE/PLYMOUTH 6
`
`the brake booster
`
`.
`
`31. Reconnect the throttle linkage.
`32. Reconnect all vacuum hoses and
`wiring.
`33. Refill the cooling system. An oil
`and filter change are recommended.
`34. Reconnect the negative battery
`cable remote connection.
`35. Start the engine and check for
`leaks. Run the engine with the radia-
`tor cap off so as the engine warms
`and the thermostat opens, coolant
`can be added to the radiator. Test
`drive vehicle to check for proper
`operation.
`
`Lash Adjusters
`
`No. 1 piston will be at TDC of the
`compression stroke.
`4. Remove the timing belt cover.
`5. Remove the timing belt.
`6. Matchmark the crank angle
`sensor to the cylinder head and re-
`move the crank angle sensor.
`7. Remove both camshaft
`sprockets.
`8. Loosen the bearing caps in se-
`quence, 1 camshaft at a time. The
`bearing caps are identified for loca~
`tion. Remove the outside bearing
`caps first.
`
`NOTE: If the bearing caps are
`difficult to remove, use a plastic
`hammer to gently tap the rear fl
`part of the camshaft.
`
`9. Remove the intake and exhaust
`camshafts.
`10. Remove the cam follower as-
`semblies from the cylinder head.
`Keep the cam followers in the order
`they have been removed from the
`head for reassembly.
`11. Mark the lash adjusters for
`reassembly in their original posi-
`tions, then remove them.
`‘
`
`
`WARNING
`The camshafts and their compo-
`nents are NOT interchangeable.
`Place an identifying mark on ,
`each component. Be sure to keep
`all parts organized for proper
`reassembly in their original
`positions.
`'
`
`
`the power steering
`
`28. Install
`pump.
`29. Raise the vehicle and reconnect
`the exhaust pipe to the exhaust
`manifold.
`30. Reconnect
`vacuum line.
`
`
`18. Clean all parts well. Clean all
`casket material from the cylinder
`fiead and the engine block. Use care
`not to scratch the aluminum cylinder
`head sealing surface. Check the cyl-
`inder head for flatness using a feeler
`gauge and a straightedge. The cylin-
`der head must be flat within 0.004
`inch (0.1mm).
`19. Check the cylinder head for
`cracks or other damage.
`20. Install a new gasket and the
`cylinder head to the engine block.
`21. Install the cylinder head bolts,
`the 4 short bolts are to be installed in
`positions 7, 8, 9 and 10. Torque the
`bolts in sequence.
`'
`22. Torque the bolts in 4 steps as
`follows:
`a. First: all bolts to 25 ft. lbs. (34
`Nm).
`b. Second: all bolts to 50 ft. lbs.
`(68 Nm).
`c. Third: all bolts again to 50 ft.
`lbs. (68 Nm).
`d. Fourth: all bolts an additional
`1/4 turn.
`
`REMOVAL AND INSTALLATION
`
`NOTE: Do not use a torque
`wrench for the fourth step.
`
`2.0L (VIN Y) DOHC Engine
`
`23. Set the crankshaft to 3 notches
`BTDC before installing the rocker
`arm shafts. Install the rocker arm
`shafts with the notches in the shafts
`pointing up and toward the timing
`belt side of the engine. Torque the
`retainer bolts to 200 inch lbs. (23
`
`24. Install the valve cover.
`25. Install the timing belt using the
`recommended procedure to make
`sure the timing marks are properly
`aligned. Failure to do so will cause
`engine damage.
`26. Reconnect the cam sensor and
`the fuel injector wiring.
`27. Install the coil pack and the
`bracket.
`
`This engine is called a Dual Over
`Head Camshaft (DOHC) engine since
`it uses 2 camshafts. Care must be
`taken to make sure all valve timing
`marks align after any cylinder head
`and valve train service.
`1. Disconnect the negative battery
`cable.
`
`2. Remove the cam cover.
`
`NOTE: Always rotate the
`crankshaft in a clockwise direc-
`tion. Make a mark on the back of
`the timing belt indicating the di-
`rection of rotation so it may be
`reassembled in the same direc-
`tion if it is to be reused.
`
`3. Rotate the crankshaft clockwise
`and align the timing marks so the
`
`l
`
`6
`(
`(to(
`(( («((K
`
`‘ J,
`
`297105
`
`Cylinder head tightening sequence — 2.0L SOHC
`
`To install:
`12. Before installation, clean the
`cylinder head and cover mating sur—
`faces. Make certain that the rails are
`flat.
`.
`13. Install the lash adjuster assem-
`bly making sure the adjusters are at
`least partially full of oil. This is indi-
`cated by little or no plunger travel
`when the adjuster is depressed.
`14. Lubricate the cam followers
`with clean engine oil and install the
`cam followers in their original posi-
`tion on the lash adjuster and valve
`stem.
`.
`15. Check the camshaft journals on
`the cylinder head and the cam bear-
`ings for wear or damage. Check the
`cam lobes and rocker rollers for dam—
`age. Also, check the cylinder head oil
`holes for clogging.
`16. Check camshaft'end—play.
`17. Inspect the cam followers for '
`wear or damage. Replace as
`necessary.
`'
`18. Lubricate the camshafts with
`
`000005
`
`JCI 1016
`
`

`

`BREEZE/CIRRUS/SEBRING/STRATUS CHRYSLER CORP. 7
`
`——_—,—_—~__——.
`cator. End-play specification is
`0002—0010 in. (0.05—0.15mm).
`
`,
`
`lg g
`
`.
`
`7
`
`326323
`
`e. If excessive end—play is pre—
`
`sent, inspect the cylinder head and
`camshaft for wear;
`replace if
`necessary.
`15. If satisfied with the fit and con-
`dition of the camshafts, remove the
`'camshafts for installation of the cam
`followers.
`
`16. The hydraulic valve lash adjust-
`ers are inside the roller cam follow-
`ers. Make sure they are clean, well—
`lubricated with clean engine oil and
`properly positioned. Install the cam
`followers in their original positions
`on the hydraulic adjuster and valve
`stem.
`
`
`WARNING
`Make sure NONE of the pistons
`are at Top Dead Center when in-
`stalling the camshafts.
`
`
`17. Lubricate the camshaft bearing
`journals and cam followers with
`clean engine oil and install the cam-
`shafts. Install right and left camshaft
`bearing caps No. 2 through No. 5 and
`right side No. 6. Tighten the M6 fas-
`teners to 105 inch lbs. (12 Nm) in cor—
`rect sequence.
`.18. Apply Mopar® Gasket Maker or
`equivalent sealer to the No. 1 and left
`side No. 6 bearing caps. Install the
`
`VALVE
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`Camshaft bearing cap identification—2.4L
`engine
`
`REMOVE OUTSIDE BEARING CAPS FIRST
`
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`326324
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`_
`Camshaft bearing cap removal — 2.4L engine
`
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`cylinder Head and Valve Assembly
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`826318
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`bearing caps and tighten the M8 fas-
`teners to 250 inch lbs. (28 Nm). The
`end caps must be installed before the
`seals may be installed.
`19. Install the camshaft end seals.
`20. Install the camshaft sprockets,
`if removed. Install the timing belt us-
`ing care to make sure all timing
`marks are properly aligned, using the
`recommended procedure. Install the
`timing belt covers.
`
`
`WARNING—‘—
`Verify that all timing marks are
`correct. If the timing belt or
`sprockets are incorrectly in-
`stalled, engine damage will oc-
`cur. Take time to make sure all
`timing marks are correctly
`aligned.
`
`
`21. Clean the cylinder head cover
`and cylinder head gasket rails (mat-
`ing surfaces). Make certain the rails
`are flat.
`
`22. Install new cylinder head cover
`gaskets. Use care. DO NOT allow oil
`or solvents to contact the timing belt
`as they can deteriorate the rubber
`and cause tooth skipping. Apply
`Mopar Silicone Rubber Adhesive
`Sealant, or equivalent, at
`the
`camshaft cap corners and at the top
`edge of the 1/2 round seal.
`
`NOTE: Inspect the spark plug
`well seals for cracking and/or
`swelling and replace if necessary.
`23. Install the cylinder head cover
`assembly to the head and tighten the
`fasteners in sequence using the fol-
`lowing 3 Steps:
`a. First:
`tighten all cylinder
`head cover fasteners to 40 inch lbs.
`(4.5 Nm).
`b. Second: tighten all fasteners
`to 80 inch lbs. (9 Nm).
`c. Third: tighten all fasteners to
`105 inch lbs. (12 Nm).
`24. Install the ignition coil pack
`and connect the spark plug wiring to
`the correct spark plugs. Torque the
`coil pack retaining fasteners to 105
`inch lbs. (12 Nm).
`25. Reconnect the ground strap.
`26. Check to be sure all vacuum
`lines and remaining wiring have
`been reconnected.
`27. An oil and filter change is
`recommended.
`
`28. Connect the negative battery
`cable and test run vehicle. Check for
`leaks and for proper operation.
`
`2.5L Engine
`
`This engine uses aluminum alloy cyl-
`inder heads With 4-valves per cylin-
`
`000006
`
`JCI 1016
`
`

`

`7 \f-CHRY‘SLER CORP. BREEZE/CIRRUS/SEBRING/STRATUS
`
`
`
` 326325
`
`Camshaft bearing cap tightening sequence—4-
`2.4L engine
`'
`
`FRONT CAM CAP
`
`
`L5 mm (.060 in.)
`
`DIAMEI'ER BEAD 0F
`MOPAR GASKET MAKER
`
`
`lEFT'REAR CAM CAP
`
`326326'
`
`Camshaft bearing cap sealing ~— 2.4L engine
`
`either cylinder bank. Two overhead
`camshafts are supported by 4 bearing
`journals which are part of the head
`with the distributor driven off the
`right (firewall side) cylinder head.
`Right and left camshaft drive sprcick—
`ets are interchangeable. The sprock-
`ets and engine water pump are
`driven by the timing belt. Care must
`be taken to make sure all valve tim—
`ing marks align after cylinder head
`and valvetrain service. Please note
`that for camshaft service, the cylin—
`der head must be removed.
`
`CAUTION -.—-—-
`Fuel injection systems, remain
`under pressure, even after .the'en-
`gine has been turned OFF. The
`fuel system pressure must be re-
`lieved before disconnecting any
`fuel lines. Failure to do so may re-
`in fire and/or-personal
`injury.
`
`1. Disconnect the negative battery
`cable from the remote auxiliary
`jumper terminal.
`2. Relieve the fuel system pres—
`sure -using the recommended
`procedure.
`»
`‘
`
`
`
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`326581
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`VALVE Simsin
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`Cylinder head, camshafts and rocker assemblies — 2.5L
`engine
`
`4. Remove the timing belt covers,
`timing belt and camshaft sprockets
`using the reCommended procedure.
`5. The intake manifold is a two—
`piece unit. The upper part is a large
`air intake plenum of aluminum alloy.
`Use care working with light alloy
`parts. Remove the air intake plenum
`first, then remove the lower intake
`manifold.
`_
`6. Disconnect, label and set aside
`the spark plug wires.
`'
`7. Remove the cylinder head cover
`screws and remove the cover.
`8. Identify the rocker arm shaft
`assemblies before removal.
`9. Install the auto lash adjuster
`retainers Special Tool MD 998443 or
`equivalent to keep the auto lash ad-
`justers from falling out of the rocker
`arms when the rocker arm assembly
`is removed.
`10. Loosen the attaching fasteners
`and remove the rocker arm shaft as-
`Semblies from the cylinder head.
`11. Remove the distributor
`assembly.
`'
`.
`12. Remove the exhaust manifold
`and crossover.
`13. Remove the cylinder head bolts '
`and remove the cylinder head from
`the vehicle.
`_
`14. Remove the thrust case from
`the left head assembly and remove
`the camshaft from the rear of the
`head. If not already done, remove the
`distributor from the right cylinder
`head and remove the camshaft from
`the rear of the-head.
`15. Remove and discard the
`camshaft oil seals.
`16. The camshafts should be care-
`fully inspected for scratches or worn
`areas. If light scratches are seen,
`they may be removed with 400 grit
`sandpaper.
`If there are deep
`scratches, replace the camshaft and
`check the cylinder head for damage.
`Check the oil holes to make sure they
`are open and free of debris. If the
`
`-
`
`roller for wear or damage. Replace
`the rocker arm if worn or damaged. If
`the camshaft shows signs of wear on
`the lobes, replace it.
`To install:
`17. Camshaft end—play can be
`checked; Oil the camshaft journals
`with clean engine oil and install the
`camshaft without the rocker arm as— .
`semblies. Move the camshaft as far
`rearward as it will go. Mount a, dial
`indicator to bear on the front of the
`camshaft. Zero the indicator. Move
`the camshaft as far forward as it will
`ngnd—play should be 0.004—0."008
`in.
`(0.1—0.2mm). Maximum allowed
`end—play is 0.016 in. (0.4mm).
`18. Lubricate the camshaft journals
`and carefully install the camshaft
`into the cylinder head. Install the
`thrust case and tighten the fasteners
`to 9 ft. lbs. (13 Nm).
`19. Apply a light coating of engine
`oil to the. camshaft oil seal lip and
`install
`the camshaft seal. The
`camshaft must be installed before in-
`stalling the seal. Be sure the seal is
`installed flush with the cylinder head
`surface. Install the camshaft sprocket
`and tighten to 65 ft. lbs. (88 Nm).
`20. Install a new head gasket over
`the locating dowels in the cylinder
`head. Install the head, using care to
`. locate on top of the dowels. Install the
`10mm Allen hex head bolts with
`washers. New head bolts are recom—
`mended. Torque the head bolts in (301'—
`rect sequence. Tighten gradually,
`working in 2 or 3 steps and finally
`tighten to 80 ft. lbs. (108 Nm).
`21. Install the lower intake mani-
`' fold using new gaskets;
`22. The rocker arm shafts are
`hollow and used as a lubrication oil
`duct. Make sure all valvetrain parts
`are clean. Check the rocker arm
`mounting portion of the shafts for
`wear or damage. Replace if neces—
`sary. Check all oil holes for clogging
`
`000007
`
`JCI 1016
`
`

`

`BREEZE/ClRRUS/SEBRING/STRATUS CHRYSLER CORP. 7
`
`
`
`ALLEN HEX
`
`CVlINDER HEAD
`
`Boll AND WASHER
`
`326592
`
`Cylinder head bolt tightening
`sequence -— 2.5L engine
`
`lubricate and install on the shafts in
`their original positions.
`23. Install the rocker arm and shaft
`assemblies.
`24. Install the timing belt. This is a
`somewhat complex procedure. Use
`the recommended procedure. It is
`most important that all valve timing
`marks align properly or engine dam—
`age will result.
`25. Inspect
`the spark plug tube
`seals located on the ends of each
`tube. These seals slide onto each tube
`to seal the cylinder head cover to the
`spark plug tube. If these seals show
`signs of hardness and/or cracks, they
`should be replaced.
`26. Clean the cylinder head and
`cover mating surfaces. Install a new
`gasket and install the cover. Torque
`bolts to 88 inch lbs. (10 Nm). Recon-
`nect the spark plug Wires.
`27. Position a new upper intake
`manifold (plenum) gasket in place
`and install the upper manifold. Tor-
`que the bolts to 13 ft. lbs. (18 Nm).
`Install the bolts for the plenum sup-
`pogt brackets and connect the EGR
`28. Reconnect
`the throttle and
`speed control cables.
`29. Reconnect the TPS and idle air
`control motor electrical connectors.
`30. Reconnect the MAP and intake
`air temperature sensors.
`31. Install the air inlet resonator,
`air inlet hose and the air cleaner
`housing cover.
`32. Check to be sure all remaining
`electrical connectors have been recon—
`nected. Tighten the air
`tube
`connections.
`
`33. Refill the cooling system. An oil
`and filter change is recommended
`whenever a cylinder head has been
`removed since coolant can get into
`the oil system.
`34. Connect the negative battery
`cable. Start the engine and check for
`
`Balance Shaft
`
`REMOVAL AND INSTALLATION
`
`2.4L Engine
`
`The 2.4L engine is equipped with 2
`balance shafts installed in a carrier
`mounted to the lower crankcase.
`These balance shafts interconnect
`through gears to rotate in opposite
`directions. The gears are powered by
`a short, crankshaft-driven chain and
`rotate at 2 times the speed of the
`crankshaft. This will counterbalance
`certain reciprocating masses of the
`engine.
`An oil passage from the No. 1 main
`bearing cap through the balance
`shaft carrier support leg provides lu—
`brication to the balance shafts. This
`passage directly supplies engine oil to
`the front bearings and internal
`machined passages in the shafts that
`routes engine oil from the front to the
`rear shaft bearing journals.
`Please note that this procedure re-
`quires removal of the timing belt.
`Valvetrain timing is critical to engine
`performance and to prevent engine
`damage. Work carefully and verify all
`timing marks as the engine is
`reassembled.
`
`1. Disconnect the negative battery
`cable remote connection located on
`the left strut tower.
`
`2. Remove the accessory drive
`belts.
`_
`3. Remove the timing belt cover
`and timing belt.
`.
`4. Raise and safely support the
`vehicle.
`
`5. Place a large drain pan under
`the oil pan drain plug and drain the
`engine oil.
`6. Remove the oil pump and oil
`pan.
`7. Remove the balance shaft drive
`chain cover.
`
`8. Remove the drive chain guide
`and drive chain tensioner.
`9. Remove the gear cover retain-
`ing stud (double ended to also mount
`drive chain guide).
`10. Remove the balance shaft gear
`and chain sprocket retaining screws.
`11. Remove the drive chain and
`chain sprocket assembly by using 2
`prybars to work the sprocket back
`and forth until it is removed from the
`crankshaft.
`12. Remove the gear cover and bal-
`ance shafts.
`13. Remove the 4 balance shaft car—
`rier-to-crankcase mounting bolts and
`
`To install:
`14. Install the balance shafts into
`the carrier and place the carrier into
`proper position against the engine
`bedplate. Install and torque the 4
`mounting bolts to 40 ft. lbs. (54 Nm).
`15. Rotate the balance shafts until
`both balance shaft key ways are
`pointed up parallel to the vertical
`centerline of the engine.
`16. Install the short hub drive gear
`onto- the sprocket driven balance
`shaft and the long hub gear onto the
`chain driven shaft. Once the gears
`are installed onto the shafts, the gear
`and balance shaft key ways must be
`up and gear alignment dots properly
`meshed.
`17. Install the gear cover and re-
`taining stud fastener. Torque the
`double ended retaining stud fastener
`to 105 inch lbs. (12 Nm).
`18. Install the drive chain crank-
`shaft sprocket. Be sure to align the
`flat on the sprocket to the flat on the
`crankshaft with the sprocket facing
`front.
`19. Rotate the crankshaft until the
`No. 1 cylinder is at Top Dead Center
`(TDC). The timing marks on the
`chain sprocket should align with the
`parting line on the left side of No. 1
`main bearing cap.
`20. Place the drive chain around
`the crankshaft sprocket so the nickel
`plated link of the chain is on the No.
`1 cylinder timing mark of the crank-
`shaft sprocket.
`the balance shaft
`21. Install
`sprocket into the drive chain. Be sure
`the timing mark on the balance shaft
`sprocket (yellow dot) lines up with
`lower nickel plated link on the chain.
`22. With the key ways of the bal-
`ance shaft pointing up in the 12
`o’clock position, slide the balance
`shaft drive chain sprocket onto the
`end of the balance shaft. If necessary
`to allow for clearance, the b