Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 10

 

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Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 10

 

 

2A-24

Chapter 2 Part A Four-cylinder engines

15.5 Match-mark the position of the driveplate and backing plate

15.6 Remove the driveplate from the crankshaft

to the crankshaft and using an appropriate

tool to hold the driveplate, remove the bolts

2

Remove the transaxle assembly (see

Chapter 7).
3

On vehicles equipped with a manual

transaxle,

now is a good time to

check/replace the modular clutch assembly
(see Chapter 8).
4

To ensure correct alignment during rein-

stallation, match-mark the driveplate and
backing plate to the crankshaft so they can
be reassembled in the same position.
5

Remove the bolts that secure the fly-

wheel or driveplate to the crankshaft (see

illustration). A special tool is available a most
auto parts stores to hold the driveplate while
loosening the bolts, if the tool is not available

wedge a screwdriver in the starter ring gear
teeth to jam the driveplate.
6

Remove the driveplate from the

crankshaft (see illustration).

7

Clean the driveplate to remove any

grease and oil. Inspect it for cracks, distortion
and missing or excessively worn ring gear
teeth. Replace if necessary.
8

Clean and inspect the mating surfaces

of the driveplate and the crankshaft.
9

If the crankshaft rear main seal is leak-

ing, replace it before reinstalling the drive-
plate (see Section 16).

Installation

10

Position the driveplate and backing

plate against the crankshaft. Align the previ-
ously applied match marks. Before installing
the bolts, apply thread locking compound to
the threads.
11

Hold the driveplate with the special

holding tool, or wedge a screwdriver in the
starter ring gear teeth to keep the driveplate
from turning. Tighten the bolts to the torque

li sted in this Chapter's Specifications.

12

The remaining installation steps are the

reverse of the removal.

16 Rear main oil seal - replacement

Refer to illustrations 16.3 and 16.5
1

The one-piece rear main oil seal is

pressed into a bore machined into the rear
main bearing cap and engine block.
2

Remove the transaxle, modular clutch

assembly (if equipped) and driveplate (see
Section 15).
3

Note: Observe that the oil seal is

installed flush with the outer surface of the
block. 
Pry out the old seal with a 3/16-inch
flat blade screwdriver (see illustration). Cau-
tion: 
To prevent an oil leak, be very careful

16.3 Using a 3/16 inch flat blade screwdriver, very carefully pry

the crankshaft rear main seal out of it's bore - DO NOT nick or

scratch the sealing surfaces on the crankshaft or seal bore

16.5 Position the new seal with the words THIS SIDE OUT facing

away from the rear of the engine. Install this seal DRY! DO NOT

lubricate! Gently and evenly drive the seal into the cylinder block

until it is FLUSH with the outer surface of the block. DO NOT drive

it past flush or there will be an oil leak - the seal must be FLUSH!

Chapter 2 Part A Four-cylinder engines

2A-25

TRANSMISSION

SUPPORT

ASSEMBLY

RIGHT ENGINE

SUPPORT

ASSEMBLY

LEFT

FRAME

FRAME

RAIL

RAIL

GROUND

CABLE

TRANSMISSION

TRANSMISSION

BRACKET

17.9a Typical left engine mount (passenger's side)

17.9b Typical right engine mount (driver's side)

2A

not to scratch or otherwise damage the
crankshaft sealing surface or the seal 
bore in
the engine block.
4

Clean the crankshaft and seal bore in

the block thoroughly and de-grease the areas
by wiping them with a rag soaked in lacquer
thinner or acetone. DO NOT lubricate the lip
or outer diameter of the new seal - it must be
installed as it comes from the manufacturer -
DRY.
5

Position

the

new seal onto the

crankshaft. Note: When installing the new
seal, if so marked, the words THIS

SIDE OUT

on the seal must face out, toward the rear of
the engine. 
Using an appropriate size driver
and pilot tool, drive the seal into the cylinder
block until it is flush with the outer surface of
the block. If the seal is driven in past flush,
there will be an oil leak. Check that the seal is
flush (see illustration).
6

The remaining installation steps are the

reverse of removal.

17

Engine mounts - check and

replacement

1

Engine mounts seldom require atten-

tion, but broken or deteriorated mounts
should be replaced immediately or the added
strain placed on the driveline components
may cause damage or accelerated wear.

Check
2

During the check, the engine must be

raised slightly to remove the weight from the
mounts.
3

Raise the vehicle and support it securely

on jackstands, then position a jack under the
engine oil pan. Place a large wood block
between the jack head and the oil pan to pre-
vent oil pan damage, then carefully raise the
engine just enough to take the weight off the
mounts. Warning:

DO NOT

place any part of

your body under the engine when it's sup -

ported only by a jack!
4

Check the mounts to see if the rubber is

cracked, hardened or separated from the

metal backing. Sometimes the rubber will

split right down the center.
5

Check for relative movement between

the mount plates and the engine or frame

(use a large screwdriver or pry bar to attempt

to move the mounts). If movement is noted,

lower the engine and tighten the mount fas-

teners.
6

Rubber preservative may be applied to

the mounts to help slow deterioration.

Replacement

Refer to illustrations 17.9a, 17.9b, 17.9c,

17.9d, 17.9e and 17.9f
7

Raise the front of the vehicle and sup-

port it securely on jackstands.
8

Place a floor jack under the engine (with

a wood block between the jack head and oil
pan) and raise the engine slightly to relieve

17.9c Typical front engine mount

2A-26

Chapter 2 Part A Four-cylinder engines

17.9d Typical engine support module (front and rear

lower mounts - 1995 through 1997 models)

17.9f Typical 2.4L rear engine mount

the weight from the mounts. Note: On 1995 to

condenser (if equipped)

must

be

supported.

engine/transaxle removal.

1997 models, the front engine mount (engine

9

Remove the fasteners and detach the

10 Installation is the reverse of removal.

support module) is

attached

to the lower radi-

mount from the frame and engine (see illus-

Use thread locking compound on the mount-

ator support.

When

removing the engine sup-

trations). Caution: Do not disconnect more

ing bolts and be sure to tighten them

port module, the radiator

and

air conditioning

than one mount at a time, except during

securely.

LOWER RADIATOR

SUPPORT

FRONT

ENGINE MOUNT

DAMPER WEIGHT

(SOME MODELS)

ENGINE

SUPPORT MODULE

REAR STRUT

REAR

BRACKET

ENGINE MOUNT

SUPPORT BRACKET

(SOME MODELS)

17.9e Typical 2.0L rear engine mount

Chapter 2 Part B

V6 engine

Contents

Section

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

assembly - 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

2B

Specifications

General

Bore .........................................................................................................
Stroke......................................................................................................
Displacement...........................................................................................
Firing order..............................................................................................
Compression ratio...................................................................................
Compression pressure ............................................................................
Oil pressure

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

Camshaft

Endplay

Standard.............................................................................................
Service limit ........................................................................................

Cylinder head

Cylinder head gasket surface warpage limit...........................................

Intake and exhaust manifolds

Intake manifold warpage limit.................................................................
Exhaust manifold warpage limit..............................................................

3.29 inches
2.992 inches
152 cubic inches (2.5 liters)
1-2-3-4-5-6
9.4:1
178 psi @ 250 rpm

6 psi (minimum)
35 to 75 psi

0.004 to 0.008 inch
0.0016 inch

0.008 inch

0.008 inch
0.012 inch

Cylinder numbering

and spark plug wire

terminal locations

5

3

1

FRONT OF VEHICLE

2B-2

Chapter 2 Part B V6 engine

Oil pump

Inner rotor-to-outer rotor lobe clearance .........................................................0.003 to 0.007 inch
Outer rotor-to-housing clearance

Standard .....................................................................................................0.004 to 0.007 inch
Service limit................................................................................................ 0.0138 inch

Rotor-to-cover clearance (end clearance)....................................................... 0.0015 to 0.0035 inch

Torque specifications

Ft-lbs (unless otherwise indicated)

Camshaft sprocket bolt ....................................................................................65
Camshaft thrust case bolts.............................................................................. 108 in-lbs
Crankshaft damper/pulley bolt .........................................................................134
Crankshaft rear main seal retainer bolts ..........................................................97 in-lbs
Cylinder head bolts..........................................................................................80
EGR tube bolts.................................................................................................95 in-lbs
Engine mounting bracket bolts........................................................................33
Exhaust manifold-to-cylinder head nuts..........................................................33
Exhaust manifold-to-exhaust pipe nuts...........................................................21
Exhaust manifold heat shield bolts ..................................................................115 in-lbs
Driveplate-to-crankshaft bolts ......................................................................... 70
Intake manifold

Upper intake manifold bolts........................................................................160 in-lbs
Lower intake manifold bolts........................................................................185 in-lbs

Oil filter adapter bolts.......................................................................................17
Oil pan bolts .....................................................................................................53 in-lbs
Oil pump

Attaching bolts

M8 bolts.................................................................................................10
M10 bolts.............................................................................................. 30

Cover bolts ................................................................................................. 88 in-lbs
Pick-up tube bolts...................................................................................... 168 in-lbs
Relief valve cap bolt................................................................................... 30

Rocker arm shaft bolts .....................................................................................23
Thermostat housing bolts................................................................................ 168 in-lbs
Timing belt

Cover bolts..................................................................................................105 in-lbs
Tensioner arm assembly bolt..................................................................... 33
Tensioner pulley bolt.................................................................................. 35

Valve cover bolts..............................................................................................88 in-lbs
Water pump mounting bolt.............................................................................. 17
"Refer to Part C for additional torque specifications

1

General information

This Part of Chapter 2 is devoted to in-

vehicle engine repair procedures. 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 Specifications included in this Part

of Chapter 2 apply only to the procedures
contained

in

this Part. Part C of Chapter 2

contains the Specifications necessary for

cylinder head and engine block rebuilding.

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 performed. 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 camshafts 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 3.6 and 3.7
1

Disconnect the negative battery cable

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

Remove the air cleaner assembly (see

Chapter 4).

Chapter 2 Part B V6 engine

2B-3

3.6 Valve cover mounting bolts (arrows)

3.7 Remove and replace the seal from each spark plug tube

3

If removing the rear valve cover (near

the firewall), remove the upper intake mani-
fold (see Section 4).
4

Clearly label then remove the spark plug

wires from the valve cover (see Chapter 1 if

necessary).

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 off

the cover (see illustration). 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 spark plug tube seals. Even

if they look OK, they should be replaced (see
illustration).
8

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

9

Install the new spark plug seals onto the

tubes.

10 Install a new gasket on the cover, using

anaerobic RTV sealant to hold it in place.

11

Tighten the valve cover bolts in 3 steps

to the torque listed in this Chapter's Specifi-
cations using a criss-cross pattern starting in
the middle of the cover and working out-
wards.
12

The remaining installation steps are the

reverse of removal. When complete, run the
engine and check for oil leaks.

Spark plug tube replacement

13

Remove the applicable 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

and the recess in cylinder head with solvent,
and dry thoroughly.

16

Apply a small amount of Loctite 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 recess
with a wood block and mallet until it is fully
seated in the cylinder head.

4

Intake manifold - removal and
installation

Upper intake manifold

Removal

Refer to illustrations 4.3a, 4.3b, 4.5, 4.6, 4.7a
and 4.7b

1

Disconnect the negative battery cable

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

Remove the air filter inlet duct from the

throttle body (see Chapter 4 if necessary).
3

Clearly label and disconnect all hoses,

wires, brackets and emission lines which
attach to the intake manifold (see illustra-
tions).
4

Disconnect the accelerator cable and

2B

4.3a Disconnect the throttle position sensor connector

4.3b Disconnect the purge vacuum hose from the throttle

body fitting

2B-4

Chapter 2 Part B V6 engine

LOWER INTAKE

MANIFOLD

GASKETS

GASKETS

NUT

4.5 Exploded view of V6 engine intake and exhaust system components

cruise control cable (if applicable) from the
throttle body (see Chapter 4 if necessary).
5

Remove the bolts securing the upper

intake manifold to the right and left side sup-
port brackets (see illustration).
6

Remove the EGR tube (see illustration).

7

Loosen the upper intake manifold bolts

in a criss-cross pattern 1/4 turn at a time until
they can be removed by hand. Remove the
upper intake manifold from the engine (see
illustrations). 
If it sticks, tap the manifold
with a soft-face hammer or carefully pry it

from the lower intake manifold. Caution: Do
not pry between 
gasket sealing surfaces.
8

To minimize the chance of gasket debris

or other contamination from getting into the
engine, place clean rags into the lower intake
manifold passages.
9

Remove all traces of gasket material

from both the upper and lower intake mani-
fold by carefully scraping them using a suit-
able gasket scraper. Caution: The intake
manifold components are 
made of aluminum
and are easily nicked or gouged. Do not dam -

age 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.

10

Using a precision straightedge and

feeler gauge, check the upper and lower

intake manifold mating surfaces for warpage
(see illustration 4.22). If the warpage on any
surface exceeds the limits listed in this Chap-

ter's Specifications, the discrepant intake

manifold must be replaced or resurfaced by

an automotive machine shop.

4.7a Starting in the center and working outwards, remove the

upper intake manifold mounting bolts in a criss-cross pattern .. .

4.6 Remove the EGR tube

Chapter Part B V6 engine

2B-5

4.7b ... then remove the manifold from the engine

4.22 Check the lower intake manifold gasket surface for warpage

Installation

11

Remove the rags from the lower intake

manifold. Use a shop vacuum to remove any
contamination that may be present.
12 Install the upper intake manifold, using a
new gasket. Tighten the bolts in 3 stages,
working from the center out, to the torque
li sted in this Chapter's Specifications.
13 Install the EGR tube using new gaskets.
Tighten the bolts to the torque listed in this
Chapter's Specifications.
14

The remaining installation steps are the

reverse of removal.

Lower intake manifold

Removal

Refer to illustration 4.22
15

Perform the fuel pressure relief proce-

dure (see Chapter 4).
16

Remove the upper intake manifold (see

above).
17

Remove the fuel rail and injector assem-

bly (see Chapter 4).
18

Loosen the intake manifold nuts in the

reverse order of the tightening sequence (see

illustration 4.24), 1/4 turn at a time until they
can be removed by hand. Remove the wash-
ers.
19

Remove the lower intake manifold from

the engine. If it sticks, tap the manifold with a
soft-face hammer or carefully pry it from the

heads. Caution: Do not pry between gasket

sealing surfaces.
20

To minimize the chance of gasket debris

or other contamination from getting into the
engine, place clean rags into the cylinder
head intake passages.
21

Remove all traces of gasket material from

the upper and lower intake manifold and cylin-
der heads by carefully scraping them using a
suitable gasket scraper. Caution: The intake
manifold components and cylinder heads are
made of aluminum and 
are easily nicked or
gouged. Do not 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.
22

Using a precision straightedge and

feeler gauge, check the upper and lower
intake manifold gasket surfaces for warpage
(see illustration). Check the gasket surface
on the cylinder head also. If the warpage on
any surface exceeds the limits listed in this
Chapter's Specifications, the discrepant
component must be replaced or resurfaced
by an automotive machine shop.

Installation

Refer to illustration 4.24

23

Remove the rags from the cylinder head

intake passages. Use a shop vacuum to
remove any contamination that may be pre-
sent.

24 Install the lower intake manifold, using a

new gaskets. Tighten the nuts in three

stages, in the sequence shown (see illustra-

tion) to the torque listed in this Chapter's

Specifications.

25 Install the fuel rail (see Chapter 4).
26 Install the upper intake manifold, using a

new gasket. Tighten the bolts in three stages,

working from the center out, to the torque

li sted in this Chapter's Specifications.

27 Install the EGR tube using new gaskets.
Tighten the bolts to the torque listed in this
Chapter's Specifications.
28

The remaining installation steps are the

reverse of removal.

5

Exhaust manifold - removal and

installation

Warning: Allow the engine to cool completely
before beginning this procedure.
Note: This procedure can be used to remove
one or both of the exhaust manifolds 
as
required.

Removal

Refer to illustrations 5.3, 5.8 and 5.9
1

Disconnect the negative battery cable

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

Raise the vehicle and support it securely

on jackstands.
3

Remove the exhaust manifold heat

shield(s) (see illustration). Before attempting

2B

4.24 Lower intake manifold nut tightening sequence

5.3 Exhaust manifold heat shield bolts (arrows) (front exhaust

manifold shown) - the upper alternator bracket must be removed

to extract the upper left heat shield bolt

 

 

 

 

 

 

 

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