Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 7

 

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Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 7

 

 

1-26

Chapter 1 Tune-up and routine maintenance

V6 engine

Refer to illustration 29.15
Note: On V6 engines, the manufacturer rec-
ommends replacing the spark plugs, spark

plug wires, distributor cap and rotor at the
same time.

11

Remove the upper intake manifold (see

Chapter 2B).
12

To prevent dirt or other foreign debris

from entering the engine, place duct tape

over the openings of the lower intake mani-

fold.

13

Remove the EGR tube from the EGR

valve (see Chapter 6 if necessary).

14

Disconnect one spark plug wire from the

distributor cap. Pull only on the boot at the

end of the wire; don't pull on the wire itself.
Use a twisting motion to free the boot/wire

from the distributor. Install the removed wire

into the new distributor cap in the exact same
location. Repeat this procedure until all spark
plug wires are installed in the new cap.
15

Loosen the 2 screws and remove the old

distributor cap (see illustration). Remove the

rotor.
16 Install the new rotor and distributor cap

(with spark plug wires attached).

17

Replace the spark plugs as described in

Section 27, except do not reattach the spark

plug wires to the retaining clips.
18

Replace the spark plug wires one at a

ti me to avoid mixing up the firing order and
make sure the terminals are securely seated
on the distributor cap and the spark plugs.

Install the plug wires using a twisting motion

on the boot until it is firmly seated. Attach the
spark plug wire to any retaining clips as

required.
19

Using a new gasket, install the EGR

1

The manufacturer does not suggest

tube onto the EGR valve (see Chapter 6).

periodic fuel filter replacement on JA series

Tighten the bolts to the torque given in the

models. See Chapter 4 if the fuel filter

Specification Section of Chapter 6.

requires replacement due to a fuel restriction

20

Remove the duct tape from the lower

or fuel contamination problem.

intake manifold.
21

Install the upper intake manifold (see

Chapter 2B).

29.15 Distributor cap

retaining screw locations

(V6 engines only)

30 Fuel filter - replacement

Chapter 2 Part A

Four-cylinder engines

Contents

Section

Balance shafts (2.4L engine) ..........................................See Chapter 2C
Camshafts - removal, inspection and installation ................................10
Camshaft oil seal - replacement ............................................................8
CHECK ENGINE light ....................................................... See Chapter 6
Crankshaft front oil seal - replacement ................................................. 7
Cylinder head - removal and installation ..............................................12
Engine mounts - check and replacement ............................................ 17
Exhaust manifold - removal and installation..........................................5
Driveplate - removal and installation ....................................................15
General information................................................................................1
Intake manifold - removal, inspection and installation .......................... 4

Section

Oil pan - removal and installation........................................................ 13
Oil pump - removal, inspection and installation ...................................14

Rear main oil seal - replacement.........................................................16
Repair operations possible with the engine in the vehicle.................... 2
Rocker arm and hydraulic valve lash adjuster - removal,

inspection and installation ................................................................9

Timing belt - removal, inspection and installation ................................. 6
Top dead center (TDC) for number one piston .............. See Chapter 2C
Valve cover - removal and installation...................................................3
Valve springs, retainers and seals - replacement ................................11

Specifications

General

Bore.........................................................................................................

Stroke

2.0L....................................................................................................
2.4L....................................................................................................

Compression ratio

2.0L....................................................................................................
2.4L....................................................................................................

Compression pressure............................................................................

Displacement

2.0L....................................................................................................
2.4L....................................................................................................

Firing order..............................................................................................
Oil pressure

At idle speed......................................................................................
At 3000 rpm .......................................................................................

3.445 inches

3.268 inches
3.976 inches

9.8:1
9.4:1

Front

170 to 225 psi

Of

Vehicle

122 cubic inches
148 cubic inches
1-3-4-2

4 psi (minimum)
25 to 80 psi

Cylinder numbering and coil

terminal locations

2A-2

Chapter 2 Part A Four-cylinder engines

Camshaft

Bearing journal diameter

2.0L

No. 1.............................................................................................
No. 2.............................................................................................
No. 3.............................................................................................
No. 4.............................................................................................
No. 5.............................................................................................

2.4L ....................................................................................................

Bearing bore diameter

2.0L

No. 1..............................................................................................

No. 2.............................................................................................
No. 3.............................................................................................
No. 4.............................................................................................
No. 5.............................................................................................

2.4L....................................................................................................

Bearing clearance...................................................................................
Endplay

2.0L
2.4L

Lobe lift

2.0L

Intake............................................................................................
Exhaust.........................................................................................

2.4L

Intake............................................................................................
Exhaust.........................................................................................

Cylinder head

Head gasket surface warpage limit .........................................................
Exhaust manifold mounting surface warpage limit .................................

Intake and exhaust manifolds

Warpage limit..........................................................................................

Rocker arm shaft assemblies (2.0L engine only)

Rocker arm shaft diameter ......................................................................
Rocker arm inside diameter ....................................................................
Rocker arm-to-shaft clearance ...............................................................
Rocker arm shaft retainer width

Intake.................................................................................................
Exhaust

No. 1 and No. 5............................................................................
No. 2, No. 3 and No. 4..................................................................

Oil pump

Cover warpage limit................................................................................
Inner rotor thickness

2.0L....................................................................................................
2.4L....................................................................................................

Outer rotor thickness

2.0L....................................................................................................
2.4L....................................................................................................

Outer rotor diameter ................................................................................
Rotor-to-pump cover clearance ..............................................................
Outer rotor-to-housing clearance............................................................
Inner rotor-to-outer rotor lobe clearance ................................................
Pressure relief spring free length .............................................................

Torque specifications

Camshaft bearing cap bolts

M6 bolts .............................................................................................
M8 bolts .............................................................................................

Camshaft position sensor bolts

2.0L....................................................................................................
2.4L....................................................................................................

1.619 to 1.6199 inches
1.634 to 1.635 inches
1.650 to 1.651 inches
1.666 to 1.668 inches
1.682 to 1.6829 inches
1.021 to 1.022 inches

1.622 to 1.6228 inches
1.637 to 1.638 inches
1.653 to 1.654 inches
1.669 to 1.670 inches
1.685 to 1.6858 inches
1.024 to 1.025 inches
0.0027 to 0.003 inch

.................................................................................................
.................................................................................................

0.0059 inch
0.002 to 0.006 inch

0.307 inch
0.277 inch

0.324 inch
0.256 inch

0.004 inch maximum
0.006 inch maximum (per foot)

0.006 inch maximum (per foot)

0.786 to 0.7867 inch
0.787 to 0.788 inch
0.0006 to 0.0021 inch

1.12 inches

1.14 inches
1.59 inches

0.003 inch

0.301 inch (minimum)
0.370 inch (minimum)

0.301 inch (minimum)
0.370 inch (minimum)
3.148 inch (minimum)
0.004 inch
0.015 inch (maximum)
0.008 inch (maximum)

2.39 inches (approximate)

Ft-lbs (unless otherwise indicated)

105 in-lbs

250 in-lbs

85 in-lbs
20

Chapter 2 Part A Four-cylinder engines

2A-3

Torque specifications (continued)

Ft-lbs (unless otherwise indicated)

Camshaft sprocket/pulley bolt

2.0L.............................................................................................................85
2.4L.............................................................................................................75

Crankshaft damper bolt................................................................................... 100 to 105
Cylinder head bolts

Step 1 .....................................................................................................25
Step 2....................................................................................................50
Step 3....................................................................................................50
Step 4....................................................................................................Tighten an additional 1/4 turn (90-degrees)

Engine mounting bracket bolts........................................................................30 to 45
Exhaust manifold-to-cylinder head bolts .........................................................200 in-lbs
Exhaust manifold-to-exhaust pipe bolts ..........................................................20
Exhaust manifold heat shield bolts .................................................................. 105 in-lbs
Front engine mount strut and structural collar bolts (1998 2.4L engine only) (see illustration 13.16)

Bolts 1 through 3........................................................................................ 75
Bolts 4 through 8........................................................................................ 45

Driveplate-to-crankshaft bolts ......................................................................... 70
Intake manifold bolts

2.0L (plastic manifold) .................................................................................105 in-lbs
2.4L (aluminum manifold) ........................................................................... 200 in-lbs

Oil filter adapter fastener ..................................................................................60
Oil pan bolts .....................................................................................................105 in-lbs
Oil part-to-transaxle structural collar bolts (1997 2.4L and 1998 2.0L engines only)

Step 1 (collar-to-oil pan bolts) .................................................................... 30 in-lbs
Step 2 (collar-to-transaxle bolts) ................................................................ 80
Step 3 (collar-to-oil pan bolts) .................................................................... 40

Oil pump

Attaching bolts............................................................................................250 in-lbs

Cover screws..............................................................................................105 in-lbs
Pick-up tube bolt........................................................................................ 250 in-lbs
Relief valve cap bolt................................................................................... 30

Rocker arm shaft bolts (2.0L) ...........................................................................250 in-lbs

Thermostat housing bolts................................................................................ 200 in-lbs
Timing belt

Cover bolts

2.0L........................................................................................................105 in-lbs
2.4L

Outer-to-inner attaching bolts ......................................................... 40 in-lbs

Inner cover-to-head/oil pump bolts.................................................105 in-lbs

Tensioner bolts

Mechanical type ......................................................................................... 250 in-lbs
Hydraulic type

Tensioner pulley assembly plate bolts ..................................................23
Tensioner unit bolts...............................................................................23
Tensioner pulley bolt.............................................................................30

Timing belt idler pulley bolt (2.4L)....................................................................45
Valve cover bolts..............................................................................................105 in-lbs
Water pump mounting bolt.............................................................................. 105 in-lbs
*Refer to Part C for additional torque specifications

2A

2A-4

Chapter 2 Part A Four-cylinder engines

3.6a Remove the valve cover mounting bolts .. .

L

3.6b ... and lift the cover and gasket off the cylinder head

1

General information

This Part of Chapter 2 is devoted to in-

vehicle engine repair procedures on models
equipped with 2.0 liter and 2.4 liter four-cylin-
der engines. Information concerning engine
removal and installation and engine block
and cylinder head overhaul can be found in
Part C of this Chapter.

The following repair procedures are

based on the assumption that the engine is
installed in the vehicle. If the engine has been
removed from the vehicle and mounted on a
stand, many of the steps outlined in this Part
of Chapter 2 will not apply.

The Specification Section included in

this Part of Chapter 2 apply only to the proce-
dures contained in this Part. Part C of Chap-
ter 2 contains the Specification Section nec-
essary for cylinder head and engine block
rebuilding.

There are two four-cylinder engines

installed in the models covered in this man-
ual; the 2.0L Single Overhead Camshaft
(SOHC) engine and the 2.4L Double Over-
head Camshaft (DOHC) engine. The main dif-
ference between the 2.0 liter and 2.4 liter
engines, besides the obvious engine dis-
placement, is the incorporation of two bal-
ance shafts installed below the crankshaft of
the 2.4L engine. For service information on
the balance shafts refer to Part C of this
Chapter.

2

Repair operations possible with
the engine in the vehicle

Many major repair operations can be

accomplished without removing the engine
from the vehicle.

Clean the engine compartment and the

exterior of the engine with some type of
degreaser before any work is done. It will
make the job easier and help keep dirt out of
the internal areas of the engine.

Depending on the components involved,

it may be helpful to remove the hood to

improve access to the engine 'as repairs are
performed (refer to Chapter 11 if necessary).
Cover the fenders to prevent damage to the
paint. Special pads are available, but an old
bedspread or blanket will also work.

If vacuum, exhaust, oil or coolant leaks

develop, indicating a need for gasket or seal

replacement, the repairs can generally be
made with the engine in the vehicle. The
intake and exhaust manifold gaskets, oil pan

gasket, camshaft and crankshaft oil seals
and cylinder head gasket are all accessible
with the engine in place.

Exterior engine components, such as

the intake and exhaust manifolds, the oil pan,
the oil pump, the water pump, the starter

motor, the alternator, the distributor and the

fuel system components can be removed for

repair with the engine in place.

Since the camshaft(s) and cylinder head

can be removed without pulling the engine,
valve component servicing can also be
accomplished with the engine in the vehicle.

Replacement of the timing belt and sprockets
is also possible with the engine in the vehicle.

In extreme cases caused by a lack of

necessary equipment, repair or replacement

of piston rings, pistons, connecting rods and

rod bearings is possible with the engine in the

vehicle. However, this practice is not recom-

mended because of the cleaning and prepa-
ration work that must be done to the compo-
nents involved.

3

Valve cover - removal and

installation

Removal

Refer to illustrations 3.6a and 3.6b

1

Disconnect the negative battery cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).
2

Remove the ignition coil pack from the

valve cover (see Chapter 5).
3

Remove the spark plug wires (see Chap-

ter 1).
4

On 2.4L engines, disconnect the ground

strap from the valve cover.

5

Clearly label and then disconnect any

emission hoses and electrical cables which
connect to or cross over the valve cover.
6

Remove the valve cover bolts and lift the

cover off (see illustrations). If the cover
sticks to the cylinder head, tap on it with a
soft-face hammer or place a wood block
against the cover and tap on the wood with a
hammer. Caution: If you have to pry between
the valve cover and the cylinder head, be

extremely careful not to gouge or nick the
gasket surfaces of either part. A leak could

develop after reassembly.
7

Remove the valve cover gasket, 1/2

round seal (2.4L engines) and spark plug tube
seals. Thoroughly clean the valve cover and
remove all traces of old gasket material. Gas-
ket removal solvents are available from auto
parts stores and may prove helpful. After
cleaning the surfaces, degrease them with a
rag soaked in lacquer thinner or acetone.

Installation

Refer to illustrations 3.8 and 3.9

8

Install the new spark plug tube seals

(see illustration).
9

Install a new gasket on the cover,

using RTV sealant to hold it in place (see
illustration).

3.8 Install new spark plug tube seals

and make sure they are properly

seated in the cover

Chapter 2 Part A Four-cylinder engines

2A-5

3.9 Apply a light coat of RTV sealant onto the cover sealing

surfaces and install the new gasket (arrow)

3.16 After applying a small amount of Loctite No. 271 (or

equivalent) to the lower end of the tube(s) (arrows), install

it and carefully tap the tube into place until its fully seated

in the cylinder head (2.0L engine only)

2A

10

On 2.4L engines, install the half-round

seal, apply anaerobic RTV sealant to the
camshaft cap corners and at the top edges of

the half-round seal.

11

Place the cover on the engine and install

the cover bolts. Tighten the valve cover bolts

in three steps to the torque listed in this

Chapter's Specifications using a criss-cross

pattern, starting in the middle of the cover

and working outwards.

12

The remaining installation steps are the

reverse of removal. When installation is com-
plete, start the engine and check for oil leaks.

Spark plug tube replacement
(2.0L engine only)

Refer to illustration 3.16
13

Remove the valve cover (see above).

14

Grasp spark plug tube with locking pli-

ers, carefully twist back and forth and remove

the tube from cylinder head.

15

Clean the locking agent from the tube

end and the receptacle in cylinder head with
solvent and dry.

16

Apply approximately 1/8 inch wide strip

of Loctite sealer No. 271, or equivalent,
around the lower end of the tube and install

the tube into the cylinder head. Carefully tap
the tube into the receptacle with a soft face

mallet or wood block. Tap the tube in until it
is fully seated in the cylinder head (see illus-

tration).

17

Allow the Loctite to cure according to

the manufacturer's instructions.
18 Install the valve cover (see above).

4

Intake manifold - removal,
inspection and installation

Warning: Allow the engine to cool completely
before beginning this procedure.

Removal

Refer to illustrations 4.4a, 4.4b, 4.8, 4.11a

and 4.1lb

1

Relieve the fuel system pressure (see

Chapter 4).

2

Disconnect the negative battery cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).
3

Remove the air cleaner assembly (see

Chapter 4).
4

Clearly label and disconnect all vacuum

hoses, wires, brackets and emission hoses

which run to the fuel injection system, throttle

body and intake manifold (see illustrations).

5

Remove the fuel rail and injector assem-

bly (see Chapter 4).

6

Remove the throttle body (see Chap-

ter 4).
7

Remove the transaxle-to-throttle body

support bracket fasteners and loosen (only)
the fastener on the transaxle side. Be sure to
disconnect any electrical connections that
are fastened to the support bracket before
trying to move the parts out of the way.

8

Remove the EGR tube (see illustration).

9

On 2.0L engines, remove the water inlet

tube support-to-intake manifold fastener.

10

On 2.4L engines, remove the intake

manifold support bracket located on the
driver's side of the manifold.

4.4b Disconnect the power brake booster

vacuum hose from the intake manifold

(2.0L engine shown)

4.4a Disconnect the PCV valve hose

from the intake manifold fitting

(2.0L engine shown)

4.8 Remove the mounting bolts from the
EGR tube (arrows) at the intake manifold

and EGR valve (shown) and remove

the tube

2A-6

Chapter 2 Part A Four-cylinder engines

4.11a Remove the intake manifold mounting bolts in a

criss-cross pattern .. .

4.l lb . . . then remove the intake manifold from the cylinder head

11

Unbolt the intake manifold and remove it

from the engine (see illustrations). If it
sticks, lightly tap the manifold with a soft-
face hammer or carefully pry it from the head.
Caution: On 2.4L engines, do not pry
between 
gasket sealing surfaces or tap on

any fuel injector boss. On 2.0L engines, the
intake manifold is made of plastic. Although
it's pretty strong, it's not very impact resistant
so use caution when tapping on it.

Inspection

Refer to illustration 4.13

12

On 2.4L engines, remove intake mani-

fold gasket by carefully scraping all traces of

gasket material from both the cylinder head
and the intake manifold. Caution: The cylin-

der head and intake manifold are made of alu-
minum and 
are easily nicked or gouged. Don't
damage the gasket 
surfaces or a leak may
result after the work is complete. 
Gasket
removal solvents are available from auto parts
stores and may prove helpful.

13

On 2.0L engines, remove the 0-ring seal

gaskets on the intake and throttle body ports

(see illustration). Caution: The intake mani-

fold is made of plastic and can be easily dam -

aged, don't scrape too hard when removing
any dirt or residue. 
Examine the intake mani-
fold for evidence of cracks and other dam-
age. Replace if any are found.

14

Using a straightedge and feeler gauge,

check the intake manifold mating surface for
warpage. Check the intake manifold surface
on the cylinder head also. If the warpage on
any surface exceeds the limits listed in this
Chapter's Specifications, the intake manifold
and/or cylinder head must be replaced or
resurfaced by an automotive machine shop.

Installation

Refer to illustrations 4.15a and 4.15b
Note: On 2.0L engines whenever the intake
manifold is removed, the manufacturer rec-
ommends using new bolts and 
washers for
installation.
15 Install the intake manifold, using a new
gasket or 0-rings as applicable. Tighten the
bolts in three stages, in the sequence shown
(see illustrations), to the torque listed in this
Chapter's Specifications.
16

The remaining installation steps are the

reverse of removal.

5

Exhaust manifold - removal,
inspection and installation

Warning: Allow the engine to cool completely
before beginning this procedure.

Removal

Refer to illustrations 5.3, 5.4, 5.5 and 5.6

1

Disconnect the negative battery cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).
2

Set the parking brake and block the rear

wheels. Raise the front of the vehicle and
support it securely on jackstands.
3

Working under the vehicle, apply pene-

trating oil to the exhaust pipe-to-manifold
fasteners to make removal easier. Remove
the fasteners securing the exhaust pipe to the
exhaust manifold and separate them (see
illustration). 
Remove the seal ring (2.0L) or
gasket (2.4L) as applicable.
4

Disconnect the wiring harness from the

upstream oxygen sensor (see illustration).
5

Remove the bolts that secure the heat

shield to the exhaust manifold and remove
the heat shield (see illustration).

4.13 On 2.0L engines, remove the 0-ring seal gaskets (arrows) on

the throttle body and intake ports

4.15a Intake manifold bolt tightening sequence (2.0L engine)

Chapter

2

Part

Four-cylinder engines

2A-7

4.15b Intake manifold bolt tightening sequence (2.4L engine)

5.3 Using a box wrench on the nuts and a socket on the bolt,

remove the shoulder bolts, springs and nuts securing

the exhaust pipe to the exhaust manifold

5.4 Follow the harness from the upstream

oxygen sensor (arrow) and disconnect

it at the connector

6

Remove the exhaust manifold mounting

bolts and remove the exhaust manifold (see
illustration). Note: 
The exhaust pipe may have

to be removed from the vehicle to facilitate
manifold removal 
(see Chapter 4 if necessary).

Inspection

7

Using a wire brush, clean the exhaust

manifold bolts, replacing any that exhibit
thread damage.

8

Using a scraper, remove all traces of

gasket material from the exhaust flange mat-
ing surfaces and inspect them for wear and
cracks. Caution: When removing gasket

material, be very careful not to scratch or
gouge the sealing surface. Any damage to the
surface may a 
leak after reassembly. Gasket
removal solvents are available from auto parts
stores and may prove helpful.
9

Using a straightedge and feeler gauge,

check the exhaust manifold-to-cylinder head
mating surface for warpage. Check the sur-
face on the cylinder head also. If the warpage
exceeds the limits listed in this Chapter's
Specifications, the exhaust manifold and/or
cylinder head must be replaced or resurfaced
by an automotive machine shop.

Installation

10

Apply Loctite No. 271 to the mounting

bolt threads prior to installation.
11

Install the new gasket (use no sealant),

manifold and bolts. Tighten the bolts in three
stages, working from the center out, to the

torque listed in this Chapter's Specifications.

12

The remaining installation steps are the

reverse of removal. Install a new gasket or

seal ring (as applicable) between the exhaust

manifold and exhaust pipe.
13

Run the engine and check for exhaust

leaks.

6

Timing belt - removal, inspection
and installation

Caution: If the timing belt failed with the
engine operating, damage to the valves may
have occurred. Perform an engine compres-

sion check after belt replacement to deter-

mine if any valve damage is present.

Removal
Refer to illustrations 6.4, 6.5, 
6.8a, 6.8b, 6.9a,

6.9b, 6.11 and 6.12
Caution: Do not turn the crankshaft or

camshaft(s) after the timing belt has been
removed,

as

this will damage the valves from

contact with the pistons. Do not try to turn
the crankshaft with the camshaft(s) sprocket
bolt(s) and do not rotate the crankshaft coun-
terclockwise.

2A

5.5 Remove the exhaust manifold heat shield mounting bolts

(arrows) and remove the heat shield

5.6 Remove the exhaust manifold mounting bolts (arrows) and

separate the exhaust manifold from the cylinder head

 

 

 

 

 

 

 

Content   ..  5  6  7  8   ..