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Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 12

2B-14

Chapter 2 Part B V6 engine

STRETCHED

BOLT

UNSTRETCHED BOLT

12.18 Place a precision straightedge along the cylinder head bolt

thread profile as shown, if any part of the bolt threads are not on

the straightedge, the bolt is stretched and must be replaced

12.19a Checking the cylinder head-to-engine block gasket

surface for warpage

12.19b Checking the engine block head gasket surface

for warpage

12.22 When installing the head gasket onto the block, make sure

all passages in the block align with the holes in the gasket

ing and tapping the wood with a hammer or
by prying the head with a prybar placed care-

fully on a casting protrusion. Note: If further
disassembly of the cylinder head is required,
refer to Part C of this Chapter.

Remove all traces of old gasket material

from the block and head. Special gasket

removal solvents that soften gaskets and
make removal much easier are available at
auto parts stores. Caution: The cylinder head

is aluminum, be very

careful not to gouge the

sealing surfaces. When working on the block,

place clean shop rags into the cylinders to
help keep out debris. Use a vacuum to
remove any contamination from the engine.
Use a tap of the correct size to chase the

threads in the engine block. Clean and

inspect all threaded fasteners for damage.
18 Inspect the cylinder head bolt threads

for "necking," where the diameter of threads
narrow due to bolt stretching (see illustra-
tion). If any cylinder head bolt exhibits dam-
age or necking, it must be replaced.

Using a precision straightedge and

feeler gauge, check all gasket surfaces for
warpage (see illustrations). 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.
20

Refer to Part C of this Chapter for clean-

ing and inspection of the cylinder head.

12.23 Install the head bolt washers

as shown

Installation

Refer to illustrations 12.22, 12.23 and 12.24

Install the camshaft(s) if removed (see

Section 10).
22

Place a new gasket on the engine block

(see illustration). Use no sealer unless indi-
cated by the gasket manufacturer. Note any
directions printed on the gasket such as
"Front" or "This side up." Place the cylinder
head(s) in position on the engine block.

23 Install the washers onto the cylinder

head bolts as shown (see illustration). Apply

clean engine oil to the cylinder head bolt
threads and install them into the cylinder

head.

Tighten the cylinder head bolts in the

sequence shown (see illustration) progress-

12.24 Cylinder head bolt

TIGHTENING sequence

ing in three stages to the torque listed in this
Chapter's Specifications.
25

The remaining installation steps are the

reverse of removal.
26

Refill the cooling system and check all

fluid levels (see Chapter 1 if necessary).

Start the engine and let it run until nor-

mal operating temperature is reached. Check

for leaks and proper operation.

Chapter 2 Part B V6 engine

2B-15

13.5 Engine oil dipstick tube mounting

bolt (arrow) - exhaust manifold heat shield

removed for clarity

13.10 If the pan is stuck, tap it with a soft-

face hammer or place a wood block

against the pan and tap the wood block

with a hammer to jar it loose

13.11a Lower the front of the oil pan to

access the oil pump pick-up tube and

remove the mounting bolts .. .

13.11 b . . . then remove the oil pump pick up tube from

the pump body

13.12 With the oil pump pick up tube removed, the oil pan can

then be withdrawn over the engine support module (arrow)

13 Oil pan - removal and installation

Removal

Refer to illustrations 13.5, 13.10, 13.11a,

13.11b, 13.12, 13.13a and 13.13b

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 accessory drivebelt splash

shield (see Chapter 1).
4

Drain the engine oil (see Chapter 1).

Remove the dipstick tube (see illustra-

tion).

Remove the starter motor (see Chap-

ter 5).
7

Remove the engine-to-transmission

support brackets.
8

Remove the exhaust manifold cross-

over pipe (see Section 5).
9

Remove the transaxle inspection cover.

Remove the mounting bolts and sepa-

rate the oil pan from the engine block enough
to facilitate oil pump pickup tube removal. If
the pan is stuck, tap it with a soft-face ham-
mer (see illustration) or place a wood block

13.13a Thoroughly clean the oil pan and

engine block gasket surfaces with a

scraper to remove all traces of old

gasket material

against the pan and tap the wood block with
a hammer. Caution: If you're wedging some-
thing between the oil pan and the engine

block to separate them, be extremely careful
not to gouge or nick the gasket surface of
either part; an oil leak could result.

Remove the oil pump pickup tube and

screen assembly (see illustrations).

Remove the oil pan from the vehicle

(see illustration).

Thoroughly clean all gasket sealing sur-

faces. Use a scraper to remove all traces of
old gasket material (see illustrations). Gas-
ket removal solvents are available at auto
parts stores and may prove helpful. Check
the oil pan sealing surface for distortion.

13.13b Remove the old gasket from the

oil pump pick up tube

2B-16

Chapter 2 Part B V6 engine

13.14 Apply a 1/8-inch bead of RTV

sealant to the oil pan sealing surface as

shown - stay on the inside of the

bolt holes

Straighten or replace as necessary. After

cleaning and straightening (if necessary),
wipe the gasket surfaces of the pan and

block clean with a rag soaked in lacquer thin-
ner or acetone.

Installation

Refer to illustration 13.14

Apply a 1/8-inch bead of RTV sealant to

the oil pan as shown (see illustration). Also

apply a light coating of RTV sealant to the
underside of the oil pan bolt heads.
15

Place the oil pan into position under the

engine block and install the oil pump pick-up
tube. Tighten the bolts to the torque listed in
this Chapter's Specifications.

Place the oil pan against the engine

block and install the bolts. Working from the

center and proceeding outward in a criss-
cross pattern, tighten the oil pan bolts to the
torque listed in this Chapter's Specifications.

The remaining installation steps are the

reverse of removal.

Lower the vehicle and fill the crankcase

with the proper quantity and grade of engine
oil (see Recommended lubricants and fluids
at the beginning of Chapter 1) and run the
engine, checking for leaks. Road test the
vehicle and check for leaks again.

14 Oil pump - removal, inspection

and installation

Removal

Refer to illustrations 14.7, 14.8, 14.9 and
14.10
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 drivebelts (see Chapter 1).

Remove the timing belt (see Section 6)

and crankshaft sprocket and Woodruff key
(see Section 7).
5

Remove the oil pan (see Section 13).

If equipped, remove the air conditioning

compressor bracket from the engine and
position it out of the way.
7

Remove the bolts and detach the oil

pump assembly from the engine (see illus-

tration). Caution: If the pump doesn't come
off by hand, tap it gently with a soft-faced
hammer or pry on a casting boss.
8

Remove the oil filter passage 0-ring

14.7 Remove the oil pump assembly mounting bolts (arrows) and

detach it from the engine - bolt (A) also secures the air

conditioning compressor bracket (if equipped)

14.8 The oil filter passage 0-ring seals (arrows) may remained

attached to the engine block

14.9 Remove the rotor cover mounting screws (arrows)

14.10 The alignment mark has worn off the inner rotor on this oil

pump; in this case we'll use a permanent marker to match-mark

the rotors for reinstallation - oil pressure relief cap bolt (A)

Chapter 2 Part B V6 engine

2B-17

14.16a Install the rotors into the oil pump

body with the match marks aligned

14.16b Use a feeler gauge to measure the

inner rotor-to-outer rotor lobe clearance

14.16c Measuring the outer rotor-to-

pump body clearance

seals and discard them. They may stick to
the engine block as shown (see illustration)
or remain in the oil pump housing.
9

Remove the oil pump rotor cover (see

illustration).
10

New rotors are manufactured with

arrows on them which are aligned at installa-
tion. If both arrows are not clearly visible (see
illustration), use a permanent marker to
match-mark the rotors so they can be
installed back in their original position.
Remove the inner and outer rotor from the
body. Caution: Be very careful with these

components. Close tolerances are critical in
creating the correct oil pressure. Any nicks or
other damage will require replacement of the
complete pump assembly.

Using a hammer and drift, carefully and

evenly drive the crankshaft front seal from the
oil pump housing and discard it.

Disassemble the oil pressure relief valve

assembly, taking note of the way the relief
valve piston is installed. Unscrew the cap bolt
and remove the bolt, washer, spring and
relief valve (see illustration 14.10).

Thoroughly clean all gasket sealing sur-

faces. Use a scraper to remove all traces of
old gasket material. Gasket removal solvents

are available at auto parts stores and may
prove helpful. Check the oil pan sealing sur-
face for distortion. Straighten or replace as
necessary. After removing the residual gasket
material, wipe the gasket surfaces of the oil
pan and block clean with a rag soaked in lac-
quer thinner or acetone.

Inspection

Refer to illustrations 14.16a, 14.16b, 14.16c,
and 14.16d

Clean all oil pump components with sol-

vent and inspect them for excessive wear
and/or damage. Replace as required. Note: if
either rotor is damaged, they must be
replaced as a set.

15 Inspect the oil pressure relief valve pis-

ton sliding surface and valve spring for dam-
age. Note: If either the spring or the valve is
damaged, they must be replaced as a set.

16 Install the rotors into the pump housing

with the match-marks aligned (see illustra-
tion). Check the oil pump rotor clearances
using a precision straightedge and feeler
gauges (see illustrations). Compare the
results to the tolerances listed in this Chap-
ter's Specifications. Replace both rotors if
any clearance is out of tolerance.

Installation

Refer to illustration 14.19
17

Lubricate the relief valve piston, piston

bore and spring with clean engine oil. Install
the relief valve piston into the bore maintain-
ing original orientation followed by the spring
and cap bolt. Tighten the cap bolt to the
torque listed in this Chapter's Specifications.
Note: If the relief valve piston is installed

incorrectly, serious engine damage could

occur.
18

Lubricate the oil pump rotor recess in

the housing and the inner and outer rotors

with clean engine oil. Install the rotors into the
pump housing with the match-marks aligned
(see illustration 14.16a). Next, fill the rotor
cavity with clean engine oil and install the
cover. Tighten the cover screws to the torque
li sted in this Chapter's Specifications.
19 Install new 0-ring seals in the oil pump
passages located on the pump body (see
illustration). If necessary, apply a light coat-
ing of grease on the 0-rings to hold them in
place.

20 Install the new crankshaft front seal into
the oil pump housing (see Section 7).
21

Apply a 1/8 inch bead of anaerobic

sealant to the oil pump body sealing surface,

14.16d Place a precision straightedge over the rotors and

measure the clearance between the rotors and the straightedge

to determine the rotor-to-cover clearance

14.19 Install new 0-ring seals on the oil filter passages (arrows)

2B-18

Chapter 2 Part B V6 engine

15.5 Remove the flywheel/driveplate from the crankshaft

16.3 Carefully

pry

the crankshaft seal out of the bore - DO NOT

nick or scratch the crankshaft or seal bore

and position the pump assembly on the block
aligning the inner rotor and crankshaft drive
flats. Install the mounting bolts.
22 If equipped, install the air conditioning
bracket onto the engine (one bolt secures
both the air conditioning bracket and the oil
pump housing).
23

Tighten the oil pump attaching bolts

(see illustration 14.7) to the torque listed in

this Chapter's Specifications.

24 Install the Woodruff key, crankshaft tim-
ing belt sprocket (see Section 7) and timing
belt (see Section 6).

25 Install the oil pan (see Section 13).
26 If applicable, install a new oil filter (see

Chapter 1).

The remaining installation steps are the

reverse of removal.

Lower the vehicle and fill the crankcase

with the proper quantity and grade of oil (see
Recommended lubricants and fluids Section

in Chapter 1).

Connect the negative battery cable to

the ground stud.
30

After the sealant has cured per the man-

ufacturer's directions, start the engine and

check for leaks.

Driveplate - removal and

installation

Removal

Refer to

illustration 15.5

Raise the vehicle and support it securely

on jackstands.
2

Remove the transaxle assembly (see

Chapter 7).
3

To ensure correct alignment during rein-

stallation, match-mark the backing plate and
driveplate to the crankshaft before removal.
4

Remove the bolts securing the drive-

plate to the crankshaft. A 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 ring
gear teeth to jam the driveplate.
5

Remove the driveplate from the crank-

shaft (see illustration).
6

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.
7

Clean and inspect the mating surfaces

of the driveplate and the crankshaft. Check
the crankshaft rear main seal for leakage; if
leakage is evident replace it before rein-
stalling the driveplate (see Section 16).

Installation

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.
9

Hold the driveplate with the special

holding tool, or wedge

screwdriver in the

ring gear teeth to keep the driveplate from
turning as you tighten the bolts to the torque
li sted in this Chapter's Specifications.
10

The remaining installation steps are the

reverse of removal.

Rear main oil seal - replacement

Refer

to illustrations 16.3, 16.6 and 16.12

The crankshaft rear main oil seal is

pressed into a retainer and bolted to the rear
of the engine block.
2

Remove the driveplate (see Section 15).

The crankshaft rear main oil seal can be

renewed without removing the oil pan or seal
retainer. However, this method is NOT recom-
mended because the lip of the seal is quite

stiff and it's possible to cock the seal in the

retainer bore or damage it during installation.
If you want to take the chance, carefully and

evenly pry out the old seal using a 3/16 flat

blade screwdriver - do not to damage the

crankshaft sealing surface (see illustration).
Apply a light coating of clean engine oil to the
crankshaft seal journal and the lip of the new
seal then carefully tap the new seal into place

using a hammer and socket. The seal lip is

stiff, so carefully work it onto the seal journal
of the crankshaft with a smooth object like the
rounded end of a socket extension as you tap
the seal into place (see illustration 16.12).
Don't force it or you may damage the seal.

16.6 With the seal retainer supported on

wood blocks, use a hammer and drift to

drive the seal out of the retainer

The following method is recommended

and requires removal of the oil pan (see Sec-
tion 13).
5

Remove the mounting bolts from the

crankshaft rear seal retainer and separate the
retainer from the engine block.
6

Using a hammer and drift, carefully drive

the old seal out of the retainer and discard it
(see illustration).
7

Thoroughly clean all gasket sealing sur-

faces. Use a scraper to remove all traces of
old gasket material. Gasket removal solvents
are available at auto parts stores and may
prove helpful. Check the oil pan sealing sur-
face for distortion. Straighten or replace as
necessary. After removing the residual gasket
material, wipe the gasket surfaces clean
using a rag soaked in lacquer thinner or ace-

tone.

Thoroughly clean and inspect the seal

bore and sealing surface on the crankshaft.
Minor imperfections can be removed with

fine emery cloth. If there is a groove worn in
the crankshaft sealing surface (from contact
with the seal), installing a new seal will proba-

bly not stop the leak.

Install the new seal into the retainer

using a socket (or block of wood) and a ham-
mer. Drive it in until it's flush with the retainer.

Chapter 2 Part B V6 engine

2B-19

16.12 Using a rounded object like a socket extension, carefully

work the seal onto the crankshaft

17.9a Front engine mount (arrow) - exhaust manifold

removed for clarity

Apply a 1/8 inch bead of RTV sealant to

the retainer gasket sealing surface.
11

Lubricate the lip of the new seal and the

crankshaft sealing surface with a light coat of
clean engine oil.
12

Place the seal retainer in position on the

engine block and install the mounting bolts.

The seal lip is stiff, so carefully work it onto
the seal journal of the crankshaft with a
smooth object like the rounded end of a
socket extension as you tap the seal into

place (see illustration). Don't force it or you
may damage the seal. Tighten the bolts to the

torque listed in this Chapter's Specifications.

13 Install the oil pan (see Section 13).
14

The remaining installation steps are the

reverse of removal.

17 Engine mounts - check and

replacement

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 wear.

Check

During the check, the engine must be

raised slightly to relieve 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

Inspect 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 slow deterioration.

Replacement

Refer to illustrations 17.9a, 17.9b, 17.9c

17.9d and 17.9e
7

Disconnect the negative battery cable

from the ground stud on the left shock tower

(see Chapter 5, Section 1). Raise the vehicle

17.9b Rear engine mount - exhaust cross-

over pipe removed for clarity

and support 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

the weight from the mount to be replaced.

Note: On 1995 through 1997 models, the

lower front engine mount (engine support
module) is attached to the lower radiator sup-

port. When removing the engine support

module, the radiator and air conditioning con-
denser (if equipped) must be supported.
9

Remove the fasteners and detach the

17.9c Engine support module (arrow) - connects front and rear

engine mounts (1995 through 1997 models)

17.9d Right-side engine mount (arrow)

2B-20

Chapter 2 Part B V6 engine

mount from the frame and engine (see illus-
trations). Caution: Do not disconnect more
than one mount at a time, except during
engine/transaxle removal.
10 Installation is the reverse of removal.
Use thread locking compound on the mount
bolts and be sure to tighten them securely.

17.9e Transaxle

support assembly

and brackets

TRANSMISSION

SUPPORT

ASSEMBLY

TRANSMISSION

BRACKET

LEFT

FRAME

RAIL

GROUND

CABLE

Chapter 2 Part C
General engine overhaul procedures

Contents

Section

Balance shafts (2.4L four-cylinder engines only) - removal,

inspection and installation.............................................................. 15

Crankshaft inspection.......................................................................... 21
Crankshaft installation and main bearing oil

clearance check ............................................................................. 25

Crankshaft removal..............................................................................16
Compression check ...............................................................................4
Cylinder head - cleaning and inspection ..............................................11
Cylinder head - disassembly ................................................................10
Cylinder head - reassembly................................................................. 13
Cylinder honing .................................................................................... 19
Engine block - cleaning........................................................................17
Engine block - inspection.....................................................................18
Engine overhaul - disassembly sequence ............................................. 9
Engine overhaul - general information ................................................... 2
Engine overhaul - reassembly sequence .............................................23

Section

Engine rebuilding alternatives................................................................8
Engine - removal and installation ...........................................................7
Engine removal - methods and precautions ..........................................6
General information ................................................................................1
Initial start-up and break-in after overhaul ...........................................27
Main and connecting rod bearings - inspection .................................. 22
Piston rings - installation......................................................................24
Pistons and connecting rods - inspection ........................................... 20
Pistons and connecting rods - installation and

rod bearing oil clearance check ..................................................... 26

Pistons and connecting rods - removal ...............................................14
Rear main oil seal - installation.......................................See Chapter 2B

Top Dead Center (TDC) for number one piston - locating .....................3
Vacuum gauge diagnostic checks.........................................................5
Valves - servicing ................................................................................. 12

Specifications

Four-cylinder engines

General

Bore.........................................................................................................
Stroke

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

Displacement

Compression ratio

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

Firing order..............................................................................................

Oil pressure

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

Cylinder head warpage

Head gasket surface..........................................................................
Intake/exhaust manifold mounting surfaces ......................................

Valves and related components

Face angle

Seat angle ................................................................................................
Valve margin width

2.0L

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

2.4L

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

3.4446 to 3.4452 inches

3.268 inches
3.976 inches

122 cubic inches
148 cubic inches

9.8:1
9.4:1

170 to 225 psi
1-3-4-2

4 psi (minimum)
25 to 80 psi

0.004 inch maximum
0.006 inch maximum

45 to 45-1/2 degrees
44-1/2 to 45 degrees
45 degrees

0.0452 to 0.0582 inch
0.058 to 0.071 inch

0.050 to 0.063 inch
0.038 to 0.051 inch

Content .. 10 11 12 13 ..