Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 8

 

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Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 8

 

 

2A-8

Chapter 2 Part A Four-cylinder engines

1

Position the number one piston at Top

Dead Center (see Chapter 2C).
2

Disconnect the negative battery cable

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

Remove the drivebelts (see Chapter 1).

4

Loosen the large bolt in the center of the

crankshaft damper pulley. It might be very

tight, to break it loose insert a large screw-

driver or bar through the opening in the pulley

to keep the pulley stationary and loosen the

bolt with a socket and breaker bar (see illus-

tration).

5

Install a 3-jaw puller onto the damper

pulley and remove the pulley from the
crankshaft (see illustration). Use the proper
insert to keep the puller from damaging the
crankshaft bolt threads. If the pulley is diffi-

cult to remove, tap the center bolt of the

puller with a brass mallet to break it loose.

Caution: Do not use a puller that has jaws

which grip the outer diameter of the damper

as the damper and hub may separate. Use
only the type shown in the illustration.
6

After removing the crankshaft pulley,

reinstall the crankshaft bolt using an appro-
priate spacer (this will enable you to turn the

crankshaft later).
7

Remove the right (passenger side)

engine mount and the mounting bracket from
the engine (see Section 17). Note: Make sure
the engine is supported with a floor jack
placed under the oil pan. Place a wood block
on the jack head to prevent the floor jack from
denting or damaging the oil pan.
8

Remove the timing belt outer cover(s)

(see illustrations).
9

Make sure the camshaft sprocket(s) and

crankshaft timing marks align before remov -

6.4 Insert a large screwdriver or bar

through the opening in the crankshaft

pulley and wedge it against the engine

block, then loosen the bolt with a

socket and breaker bar

ing the timing belt (see illustrations). If nec-
essary, align the timing marks by rotating the
crankshaft - clockwise only! Note: If you plan
to reuse the timing belt, paint an arrow on it
to indicate the direction of rotation (clock-
wise).
10

Two different types of timing belt ten-

sioners were incorporated on these engines,
hydraulic and mechanical. The hydraulic
tensioner is easily recognizable by the sealed
hydraulic unit which maintains constant pres-
sure on the timing belt tensioner pulley. The
mechanical type has a built-in spring inside
the pulley which supplies clockwise tension
to the belt.
11

On engines equipped with a hydraulic

tensioner, loosen, then remove the timing

6.5 Install a 3-jaw puller onto the damper

pulley, position the center post of the

puller on the crankshaft end (use the

proper insert to keep from damaging the

crankshaft threads), and remove the

pulley from the crankshaft

belt tensioner mounting bolts (see illustra-

tion) and remove the tensioner. Note: The

tensioner piston will extend when the assem-

bly is removed.

12

On engines equipped with a mechanical

tensioner, insert an 8 mm (2.0L engine)

or 6 mm (2.4L engine) Allen wrench in the
hexagon fitting in the tensioner pulley. Insert

the long end of a 3 mm Allen wrench (or 1/8

inch drill bit) into the small hole on the pulley.

While applying light pressure to the Allen
wrench or drill bit, rotate the tensioner pulley

counterclockwise until the Allen wrench or
drill bit slides into the locking hole (see illus-

tration).

UPPER TIMING BOLT

COVER FASTENERS

1

LOWER TIMING

BELT COVER

FASTENERS

- INDICATES RETAINING

CLIP LOCATION

6.8a Remove the two lower bolts and upper clip retaining the

ti ming belt outer cover to the engine (2.0L SOHC engine)

6.8b Timing belt outer cover fastener locations (2.4L engine)

Chapter 2 Part A Four-cylinder engines

2A-9

6.9a Before removing the timing belt, make sure the camshaft

sprocket and crankshaft timing marks align with their respective

marks - rotate the engine (clockwise only as viewed from the

crankshaft end) as required to align both sets of timing

marks (2.0L engine timing marks)

CAMSHAFT TIMING-MARKS

6.9b 2.4L engine timing marks - The crankshaft sprocket timing

mark is on the trailing edge of the sprocket tooth

TRAILING

EDGE OF

SPROCKET

TOOTH

CRANKSHAFT TDCMARKS

2A

13

Carefully slip the timing belt off the

sprockets and set it aside. If you plan to
reuse the timing belt, store it in a plastic bag -
do not allow the belt to come in contact with
any type of oil or water as this will greatly

shorten belt life.

14 If it's necessary to remove the camshaft

sprocket(s), and/or timing belt rear cover (for
camshaft seal replacement, see Section 8).

Inspection

Refer to illustration 6.18

15 Inspect the crankshaft front oil seal for

leaks and replace it if necessary (see Sec-
tion 7)..
16 Inspect the water pump for evidence of
leakage (usually indicated by a trail of wet or
dried coolant). Check the pulley for excessive
radial play and bearing roughness. Replace if

necessary (see Chapter 3).

17

Rotate the tensioner pulley and idler pul-

ley (2.4L engines) by hand and move them
side-to-side to detect bearing roughness and
excess play. Visually inspect all timing belt
sprockets for any signs of damage or wear.
Replace parts as necessary.
18 Inspect the timing belt for cracks, sepa-
ration, wear, missing teeth and oil contamina-
tion (see illustration). Replace the belt if it's

6.11 Loosen, then remove the timing belt hydraulic tensioner

mounting bolts (arrows) and remove the tensioner

(2.0L engine shown)

ALLEN

WRENCH

6.12 To relieve the timing belt tension on mechanical type

tensioners, place the appropriate size Allen wrench in the pulley

and apply torque in a counterclockwise direction until the

retaining pin holes align and insert a 3mm Allen wrench or

1/8 inch drill bit to hold the pulley in place

2A-10

Chapter 2 Part A Four-cylinder engines

in questionable condition or the engine
mileage is close to that referenced in the

Maintenance Schedule (see Chapter 1).

19 If equipped, check the hydraulic ten-

sioner for leaks or any other obvious damage,

replace if necessary.

Installation

2.0L engine

Refer to illustrations 6.21a, 6.2 lb and 6.21c
20

Confirm that the camshaft sprocket tim-

ing marks are aligned (see illustration 6.9a).
Reposition as required.
21

Position the crankshaft timing belt

sprocket as follows (see illustrations):

a) Initially align the TDC mark on the

sprocket with the arrow on the oil pump
housing.

b) Then back it off counterclockwise 3

teeth BTDC.

c) Rotate the crankshaft sprocket clock-

wise to 1/2-tooth before the arrow mark
on the oil pump housing.

22 Install the timing belt as follows; first
place the belt onto the crankshaft sprocket,
maintaining tension on the belt, wrap it
around the water pump sprocket, camshaft

sprocket and the tensioner pulley.
23

To take the slack out of the timing belt,

rotate the crankshaft timing sprocket clock-

wise to align the timing marks (TDC), make
sure the camshaft sprocket timing marks
remain aligned.

2.4L engine

Refer to illustration 6.25
24

Confirm that the timing marks on the

camshaft sprockets are aligned (see illustra-
tion 6.9b).
25

Rotate the exhaust camshaft sprocket

clockwise so the timing mark is 1/2 tooth
below the intake camshaft timing mark as
shown (see illustration).
26

Next, align the crankshaft sprocket tim-

ing mark with the arrow mark on the oil pump
housing (see illustration 6.9b).

6.18 Carefully inspect the timing belt -

bending it backwards will often make

wear or damage more apparent

27 Install the timing belt as follows; first
place the belt onto the crankshaft sprocket,
maintaining tension on the belt, wrap it
around the water pump sprocket, idler pulley,
camshaft sprockets and the tensioner pulley.

To take up the belt slack, rotate the exhaust

camshaft counterclockwise until the timing
marks on both sprockets align.

Engines with a mechanical

tensioner

28

On engines equipped with a mechanical

tensioner, pull the retaining pin from the ten-
sioner pulley.
29

Using the bolt in the center of the

crankshaft sprocket, turn the crankshaft
clockwise two complete revolutions. Cau-
tion: 
If you feel resistance while turning the
crankshaft - STOP, the valves may be hitting
the pistons from incorrect valve timing. Stop
and re-check the valve timing. 
Note: The
camshaft and crankshaft sprocket marks will
align 
every two revolutions of the crankshaft.
30

Recheck the alignment of the timing

marks (see illustrations 6.9a and 6.9b). If
the marks do not align properly, loosen the
tensioner, slip the belt off the camshaft

6.21a On 2.0L engines, use a box-end

wrench or socket to rotate the crankshaft
ti ming sprocket until the TDC mark on the

sprocket is aligned with the arrow on the

oil pump housing (arrow) .. .

6.21b . . . then back it off

counterclockwise 3 teeth BTDC (arrows)

sprocket, realign the marks, reinstall the belt,
and check the alignment again.
31

The remaining installation steps are the

reverse of removal. Tighten the crankshaft
pulley bolt to the torque listed in this Chap-
ter's Specifications. Start the engine and
road test the vehicle.

CAMSHAFT

SPROCKET EXHAUST

CAMSHAFT

SPROCKET INTAKE

6.21c Rotate the crankshaft timing sprocket clockwise

to 1/2-tooth BTDC (arrows)

6.25 Before installing the timing belt, rotate the exhaust

camshaft sprocket clockwise so the timing mark is 1/2 tooth

below the timing mark on the intake camshaft sprocket

Chapter 2 Part A Four-cylinder engines

2A-11

6.32a The hydraulic tensioner piston (arrow) must be compressed

into the tensioner housing prior to installation

6.32b Place the tensioner in a vise with the hole (arrow) facing up.

Compress the piston with the vise and insert a 5/64 inch Allen

wrench or drill bit through the hole to keep the piston

retracted for installation

2A

Engines with a hydraulic tensioner

Refer to illustrations 6.32a, 6.32b and 6.34

32

On engines equipped with a hydraulic

tensioner, the piston must be compressed

into the tensioner housing prior to installation.
Place the tensioner in a vise with the pin
holes facing up. Slowly compress the ten-

sioner, then install a 5/64-inch Allen wrench
or drill bit through the body to retain the pis-
ton in this position (see illustrations).

Remove the tensioner from the vise.

33 Install the tensioner assembly - except
don't tighten the bolts at this time.
34

Have an assistant place a torque

wrench on the center bolt of the tensioner
pulley and apply 250 in-lbs of torque in a
clockwise direction. With the torque applied
to the tensioner pulley, move the tensioner up
against the tensioner pulley bracket and
tighten the tensioner bolts to the torque listed
in this Chapter's Specifications (see illustra-
tion). 
Remove the torque wrench.
35

Pull the Allen wrench or drill bit from the

tensioner. The timing belt tension is correct
when the pin can be withdrawn and rein-
serted easily. Verify that the timing marks on

the camshaft sprocket(s) and crankshaft

sprocket are still aligned at TDC.

36

Using the bolt in the center of the

crankshaft sprocket, turn the crankshaft

clockwise two complete revolutions. Cau-
tion: 
If you feel resistance while turning the
crankshaft - STOP, the valves may be hitting
the pistons from incorrect valve timing. Stop
and re-check the valve timing. 
Note: The
camshaft and crankshaft sprocket marks will
align every two revolutions of the crankshaft.
Recheck the alignment of the timing marks
(see illustrations 6.9a and 6.9b). If the
marks do not align properly, loosen the ten-
sioner, slip the belt off the camshaft
sprocket(s), realign the marks, reinstall the
belt, and check the alignment again.
37

After crankshaft rotation, recheck the

ti ming belt tension by inserting the retaining
pin (5/64-inch Allen wrench or drill bit) back
into the tensioner. If the retaining pin cannot

be inserted and withdrawn freely, readjust the
ti ming belt tension and repeat Steps 34
through 37.
38

The remaining installation steps are the

reverse of removal. Tighten the crankshaft
pulley bolt to the torque listed in this Chap-
ter's Specifications.
39

Start the engine and road test the vehi-

cle.

7

Crankshaft front oil seal -
replacement

Refer to illustrations 7.2, 7.3, 7.5 and 7.6
Caution: Do not rotate the camshaft(s) or
crankshaft when the timing belt is removed or
damage to the engine may occur.

1

Remove the timing belt (see Section 6).

2

Remove the crankshaft timing belt

sprocket from the crankshaft with a bolt-type
gear puller (see illustration). Remove the
Woodruff key from the crankshaft keyway.

LOCKING PIN

INSTALLED
INTO THE

TENSIONER

6.34 Using a torque wrench on the tensioner pulley bolt, apply 250

inch-lbs of torque as shown, move the hydraulic tensioner up

against the tensioner pulley bracket and tighten the tensioner

mounting bolts to the torque listed in this Chapter's Specifications

7.2 Attach a bolt-type gear puller to the crankshaft sprocket and

remove the sprocket from the crankshaft

2A-12

Chapter 2 Part A Four-cylinder engines

7.3 Using a screwdriver, very carefully pry

the front crankshaft seal from it's bore

8.4a Remove the hydraulic tensioner

pulley/plate assembly mounting

bolts (arrows) .. .

3

Wrap the tip of a small screwdriver with

tape. Working from below the right inner
fender, use the screwdriver to carefully pry
the seal out of its bore (see illustration).
Take care to prevent damaging the oil pump
assembly, the crankshaft and the seal bore.
4

Thoroughly clean and inspect the seal

bore and sealing surface on the crankshaft.
Minor imperfections can be removed with
emery cloth. If there is a groove worn in the
crankshaft sealing surface (from contact with

8.8 Carefully pry the camshaft seal out of

the bore - DO NOT nick or scratch the

camshaft or seal bore

7.5 Lubricate the new front crankshaft

seal with engine oil and using a hammer

and socket, drive the seal into the bore

until it's flush with the oil pump housing

8.4b . . . and then remove the pulley and

bracket assembly (2.0L engine)

the seal), installing a new seal will probably

not stop the leak.

5

Lubricate the new seal with engine oil

and using a hammer and the appropriate size

socket, drive the seal into the bore until it's
flush with the oil pump housing. (see illustra-
tion).
6

Install the Woodruff key and the

crankshaft timing belt sprocket with the word

FRONT facing out onto the crankshaft (see

illustration).
7

The remaining installation steps are the

reverse of removal. Tighten the crankshaft

pulley bolt to the torque listed in this Chap-
ter's Specifications.
8

Start the engine and check for oil leaks.

8

Camshaft oil seal - replacement

Refer to illustrations 8.4a, 8.4b, 8.7, 8.8,
8.10a, 8.10b and 8.12
Caution: Do not rotate the camshaft(s) or
crankshaft when the timing belt is removed or
damage to the engine may occur.
1

Remove the timing belt (see Section 6).

2

Rotate the crankshaft counterclockwise

until the crankshaft sprocket is three teeth
BTDC (see illustration 6.21b). This will pre-
vent engine damage if the camshaft sprocket
is inadvertently rotated during sprocket bolt

7.6 Position the crankshaft sprocket with

the word FRONT (arrow) facing out and

install it onto the crankshaft

8.7 Remove the rear timing belt cover

removal.
3

While holding the camshaft sprocket,

remove the camshaft sprocket bolt. Then,
using two large screwdrivers, lever the
sprocket off the camshaft. Note: To hold the

camshaft/sprocket while loosening the bolt, a
strap-type damper/pulley holder tool is rec-
ommended and is available 
at most auto
parts 
stores. If the strap wrench is unavail-
able, remove the valve cover 
to access the

wrenching flats on the camshaft (2.4L
engines only).

4

On 2.0L engines, remove the 2 bolts

securing the tensioner pulley bracket to the
engine block and remove the pulley and

bracket assembly (see illustrations). Do not

attempt to loosen the center bolt on the pul-

ley or the pulley pivot bolt, remove the pulley

and bracket together.
5

On 2.4L engines, remove the idler pul-

ley.

6

On 2.0L engines equipped with a

hydraulic timing belt tensioner, remove the
tensioner pulley.
7

Remove the bolts securing the rear

cover to the engine block and cylinder head.

Remove the rear cover (see illustration).

8

Carefully pry out the camshaft oil seal

using a small screwdriver (see illustration).
Don't scratch the bore or damage the
camshaft in the process (if the camshaft is
damaged, the new seal will end up leaking).

Chapter 2 Part A Four-cylinder engines

2A-13

8.10a Using a hammer and socket, gently

tap the new seal into place with the

spring side facing inward

9

Clean the bore and coat the outer edge

of

the new seal with engine oil or multi-pur-

pose grease. Also lubricate the seal lip.
10

Using a socket with an outside diameter

slightly smaller than the outside diameter of
the seal and a hammer (see illustration),
carefully drive the new seal into the cylinder
head until it's flush with the face of the cylin-
der head. If a socket isn't available, a short
section of pipe will also work. Note: If engine
location makes it difficult to use a hammer to

install the camshaft seal, fabricate a seal
installation tool from a piece of pipe cut to the
appropriate length, a bolt and a large washer

(see illustration). Place the section of pipe

over the seal and thread the bolt into the
camshaft. The seal can now be pressed into

the bore by tightening the bolt.
11

Install the rear timing belt cover, ten-

sioner pulley/bracket, idler pulley and ten-
sioner pulley as applicable.

12 Install the camshaft sprocket, aligning

the pin in the camshaft with the hole in the
sprocket (see illustration). Use an appropri-
ate tool to hold the camshaft sprocket while
tightening the sprocket bolt to the torque
li sted in this Chapter's Specifications.

13

Reinstall the timing belt (see Section 6).

14

Run the engine and check for oil leaks.

8.10b If space is limited and you can't use

a hammer and socket to install the seal, a

seal installer can be made from a section

of pipe (of appropriate diameter), a bolt

and washer. Place the pipe over the

seal and press it into place by

tightening the bolt

9

Rocker arm and hydraulic valve
lash adjuster - removal,
inspection and installation

Removal

2.0L engine

Refer to illustration 9.6

1

Position the number one piston at Top

Dead Center (see Chapter 2C).

2

Disconnect the negative battery cable

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

Remove the valve cover (see Section 3).

4

Prior to removing the rocker arm shafts,

mark the front shaft (intake manifold side) as
the intake rocker arm shaft and the rear shaft
(exhaust manifold side) as the exhaust. Cau-
tion: 
Do not interchange the rocker arms onto
a different 
shaft as this could lead to prema-
ture 
wear.
5

Loosen the rocker arm shaft bolts 1/4 -

8.12 When installing a camshaft sprocket,

make sure the pin in the camshaft is

aligned with the hole in the

sprocket (arrows)

turn at a time each, until the valve spring
pressure is relieved, in the reverse order of
the tightening sequence (see illustration
9.20). 
Completely loosen the bolts, but do
not remove them, since leaving them in place
will prevent the assembly from falling apart
when it is lifted off the cylinder head.
6

Lift the rocker arms and shaft assem-

blies from the cylinder head and set them on
the workbench (see illustration). Note: The

hydraulic valve lash adjusters may become
dislodged from the rocker arms during shaft
removal. If required, secure the adjusters in
place using electrical tape.

7

Disassemble the rocker arm shaft com-

ponents. Caution: Before disassembly, mark
the rocker arm shafts, rocker arms, shaft

retainers and plastic shaft spacers (intake
only) so all the parts can be 
reassembled in
their original locations. To keep the rocker
arms and related parts in order, it's 
a good
idea to remove them and put them onto two
lengths of wire 
(such as unbent coat hangers)
in the 
same order as they're removed, mark-
ing 
each wire (which simulates the rocker
shaft) 
as to which end would be the front of
the engine.

2A

9.6 Intake and exhaust rocker arms and shaft assemblies

(2.0L engine)

9.9 On 2.4L engines, once the camshafts have been removed, the

rocker arms and hydraulic valve lash adjusters (located below the

rocker arm can be removed) - be sure to keep the rocker arms

and lash adjusters in order so they can be returned

to their original locations

o

2A-14

Chapter Part A

Four-cylinder engines

2.4L engine

Refer to illustration 9.9

8

Remove both camshafts (see Sec-

tion 10).

9

Once the camshafts have been

removed, the rocker arms (a.k.a. cam follow-

ers) can be lifted off (see illustration). Cau-
tion: 
Each rocker arm and valve lash adjuster
must 
be placed back in it's original location,
so mark them or place them in a marked con-
tainer (such 
as an egg carton or cupcake tray)
so they won't get mixed up.

10

Remove the rocker arms and hydraulic

valve lash adjusters from the cylinder head.

Inspection

2.0L engine

Refer to illustration 9.11
Note: The valve lash adjuster is an integral

part of each rocker arm and cannot be

replaced separately.
11

Visually check the rocker arms for wear

(see illustration). Replace them if evidence
of wear or damage is found.
12 Inspect each lash adjuster carefully for
signs of wear and damage, particularly on the
surface that contacts the valve tip. Since the
lash adjusters frequently become clogged,

we recommend replacing the rocker arm/lash
adjuster assembly if you're concerned about
their condition or if the engine is exhibiting
valve "tapping" noises.

13

Check all the rocker shaft components.

Look for worn or scored shafts, etc. and
replace any parts found to be damaged or
worn excessively.

2.4L engine

Refer to illustration 9.14

14

Visually check the rocker arm tip, roller

and lash adjuster pocket for wear (see illus-
tration). 
Replace them if evidence of wear or
damage is found.

15 Inspect each adjuster carefully for signs

of wear and damage, particularly on the ball
tip that contacts the rocker arm. Since the
lash adjusters frequently become clogged,
we recommend replacing them if you're con-
cerned about their condition or if the engine
is exhibiting valve "tapping" noises.

Installation

2.0L engine

Refer to illustrations 9.18, 9.19 and 9.20
16

Prior to installation, the lash adjusters

must be partially full of engine oil - indicated
by little or no plunger action when the
adjuster is depressed. If there's excessive
plunger travel, place the rocker arm assembly
into clean engine oil and pump the plunger
until the plunger travel is eliminated. Note: If
the plunger still travels within the rocker arm
when full of oil it's defective and the rocker

arm assembly must be replaced.

9.11 2.0L engine rocker arm/valve lash

adjuster assembly (intake rocker

arm shown)

1

Hydraulic valve lash adjuster

2

Rocker shaft bore

3

Roller

17

When assembling the rocker arms on

the shaft assembly, make sure they're rein-
stalled in their original locations.
18

On the intake rocker arm shaft, make

sure the plastic spacers are installed on the
shaft in the correct locations (see illustra-

tion).

19 Install the rocker arm assemblies with

the notch in each rocker arm shaft located at
the timing belt end of the engine and facing

UP (see illustration).

9.14 2.4L engine rocker arm

9.18 Intake rocker arm plastic spacer locations (arrows)

(2.0L engine)

TIP

9.20 Rocker arm shaft bolt tightening sequence (2.0L engine)

4

9.19 Both rocker arm shafts must be installed with the notches

(arrows) facing UP and at the timing belt end of the engine

Chapter Part A

Four-cylinder engines

2A-15

REMOVE OUTSIDE BEARING CAPS FIRST

10.7 2.4L engine camshaft bearing cap location numbers - they

must be reinstalled in their original locations

10.8 Remove the outside bearing caps first, then loosen the

remaining bearing cap bolts in the sequence shown 1/4 turn at a

ti me until they can be unscrewed by hand (2.4L engine)

20

Tighten the rocker arm bolts in

sequence shown (see illustration) using 3
steps to reach the torque listed in this Chap-
ter's Specifications.
21

The remaining installation steps are the

reverse of removal. Run the engine and
check for oil leaks and proper operation.
22

When re-starting the engine after replac-

ing the rocker arm/lash adjusters, the
adjusters will normally make "tapping"
noises. After warm-up, slowly raise the speed
of the engine from idle to 3,000 rpm and back
to idle over a one minute period. If the
adjuster(s) do not become silent, replace the
defective rocker arm/lash adjuster assembly.

2.4L engine

23

Prior to installation, the lash adjusters

must be partially full of engine oil - indicated
by little or no plunger action when the
adjuster is depressed. If there's excessive
plunger travel, place the rocker arm assembly
into clean engine oil and pump the plunger
until the plunger travel is eliminated. Note: If
the plunger still travels within the rocker arm
when full of oil it's defective and the rocker

arm assembly must be replaced.

10.12 Measure the camshaft bearing

journal diameters with a micrometer and

compare the measurements to the
dimensions given in this Chapter's

Specifications

24 Install the hydraulic lash adjusters and

rocker arms back in their proper locations on

the cylinder head.
25 Install the camshafts (see Section 10).
26

When re-starting the engine after replac-

ing the rocker arm/lash adjusters, the
adjusters will normally make "tapping"
noises. After warm-up, slowly raise the speed
of the engine from idle to 3,000 rpm and back
to idle over a one minute period. If the
adjuster(s) do not become silent, replace the
defective lash adjuster assembly.

10 Camshaft(s) - removal,

inspection and installation

Removal

2.0L engine

Note: The camshaft cannot be removed with
the cylinder head installed in the vehicle.
1

Remove the cylinder head (see Sec-

tion 12).

2

Remove the camshaft position sensor

(see Chapter 6).

3

Carefully withdraw the camshaft from

the opening in the rear of the cylinder head.
Caution: Don't damage the camshaft lobes
or bearing journals during removal and instal-
lation through the opening in the cylinder
head.
4

Remove the camshaft front seal from

the cylinder head.

2.4L engine

Refer to illustrations 10.7 and 10.8
5

Remove the timing belt (see Section 6).

6

Remove the camshaft sprockets and the

rear timing belt cover (see section 8).
7

The camshaft bearing caps are identi-

fied with their numbered location in the cylin-
der head (see illustration).
8

Remove the outside bearing caps at

each end of the camshafts first. Remove the
remaining camshaft bearing caps, loosening
the bolts a little at a time to prevent distorting
the camshaft(s) by loosening the caps in the

sequence shown (see illustration). Once the
bearing caps have all been loosened enough

for removal, they may still be difficult to

remove. Using the bearing cap bolts for extra
leverage, move the cap back and forth to
loosen the cap from the cylinder head. If they

are still difficult to remove you can tap them
gently with a soft face mallet so they can be

lifted off. Caution: Store them in order so

they can be returned to their original loca-
tions, with the same side facing forward.
9

Carefully lift the camshafts out of the

cylinder head. Mark the camshafts INTAKE
and EXHAUST, they cannot be mixed-up.

10

Remove the front seal from each

camshaft. Note: Now is a good time to
inspect the rocker arms and lash adjusters
(see Section 9).

Inspection

Refer to illustration 10.12
11

Thoroughly clean the camshaft(s) and

the gasket surface. Visually inspect the
camshaft for wear and/or damage to the lobe
surfaces, bearing journals and seal contact
surfaces. Visually inspect the camshaft bear-
ing surfaces in the cylinder head and bearing
caps (2.4L engines) for scoring and other
damage.
12

Measure the camshaft bearing journal

diameters (see illustration). Measure the
inside diameter of the camshaft bearing sur-

faces in the cylinder head, using a telescop-

ing gauge (on 2.4L engines, temporarily
install the bearing caps). Subtract the journal
measurement from the bearing measurement

to obtain the camshaft bearing oil clearance.

Compare this clearance with the value listed
in this Chapter's Specifications. Replace

worn components as required.

13

Replace the camshaft if it fails any of the

above inspections. Note: If the lobes are
worn, replace the rocker arms and lash
adjusters along with the camshaft. 
Cylinder
head replacement may be necessary if the
camshaft bearing surfaces in the head are
damaged or excessively worn.

14

Clean and inspect the cylinder head as

described in Part C of this Chapter.

2A

 

 

 

 

 

 

 

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