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1. INSTALLATION 1 Install engine mount bracket and tighten bolts to 61 N m 45 ft Ibs Fig 22 2 Install bolt attaching engine mount to bracket Fig 21 Tighten bolt to 118 N m 87 ft Ibs 3 Install mount bolt access plug Fig 20 4 Remove support from under engine 5 Install power steering air conditioning belt Refer to Group 7 Cooling System Accessory Drive Belts for procedure 6 Install upper and lower torque struts Refer to procedure in this section PL REMOVAL AND INSTALLATION Continued 80be4e9b Fig 21 Engine Mount to Bracket 1 BOLT 2 RIGHT ENGINE MOUNT 3 ENGINE MOUNT BRACKET 80bc4d2f Fig 22 Engine Mount Bracket Assembly 1 BOLTS 2 ENGINE MOUNT BRACKET ASSEMBLY STRUCTURAL COLLAR REMOVAL 1 Raise vehicle on hoist 2 0L SOHC ENGINE 9 25 NOTE To remove transaxle dust cover the front bending strut must be removed 2 Remove structural collar from oil pan to tran saxle Fig 23 80al6 ica Fig 23 Structural Collar Removal and Installation 1 OIL PAN 2 STRUCTURAL COLLAR INSTALLATION CAUTION The torque procedure for the structural collar must be followed as damage to oil pan or collar could occur 1 Install the structural collar Fig 23 using the following 3 step torque sequence e Step 1 Install the collar to oil pan bolts and tighten to 3 N m 30 in
2. Faulty coil s or control unit Incorrect spark plug gap Contamination in fuel system Faulty fuel pump Incorrect engine timing 1 Test battery Charge or replace as necessary Refer to Group 8A Battery 2 Clean and tighten battery connections Apply a coat of light mineral grease to terminals 3 Test starting system Refer to Group 8B Starting 4 Test and replace as needed Refer to Group 8D Ignition System 5 Set gap Refer to Group 8D Ignition System 6 Clean system and replace fuel filter 7 Test fuel pump and replace as needed Refer to Group 14 Fuel System 8 Check for a skipped timing belt chain ENGINE STALLS OR IDLES ROUGH Idle speed too low Incorrect fuel mixture Intake manifold leakage Faulty coil s 1 Test minimum air flow Refer to Group 14 Fuel System 2 Refer to Group 14 Fuel System 3 Inspect intake manifold manifold gasket and vacuum hoses 4 Test and replace as necessary Refer to Group 8D Ignition System ENGINE LOSS OF POWER Dirty or incorrectly gapped plugs Contamination in fuel system Faulty fuel pump Incorrect valve timing Leaking cylinder head gasket Low compression Burned warped or pitted valves Plugged or restricted exhaust system 9 Faulty coil s 1 Clean plugs and set gap Refer to Group 8D Ignition System 2 Clean system and replace fuel filter 3 Test and repl
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4. SCREWDRIVER v 2 e d E 6 7e D 9 PL INSTALLATION CAUTION If burr or scratch is present on the crankshaft edge chamfer cleanup with 400 grit sand paper to prevent seal damage during installa tion of new seal NOTE When installing seal no lube on seal is needed 1 Place Special Tool 6926 1 on crankshaft This is a pilot tool with a magnetic base Fig 90 2 Position seal over pilot tool Make sure you can read the words THIS SIDE OUT on seal Fig 90 Pilot tool should remain on crankshaft during instal lation of seal Ensure that the lip of the seal is facing towards the crankcase during installation CAUTION If the seal is driven into the block past flush this may cause an oil leak 3 Drive the seal into the block using Special Tool 6926 2 and handle C 4171 Fig 91 until the tool bot toms out against the block Fig 92 80468d52 Fig 90 Rear Crankshaft Seal and Special Tool 6926 1 1 SPECIAL TOOL 6926 1 PILOT 2 SEAL 4 Install drive plate Apply Mopar Lock amp Seal Adhesive to bolt threads and tighten bolts to 95 N m 70 ft Ibs 5 Install transaxle Refer to Group 21 Transaxle for procedure BL 2 0L SOHC ENGINE 9 51 REMOVAL AND INSTALLATION Continued 80468d53 Fig 91 Crankshaft Seal Special Tool 6926 2 L 1 SPECIAL TOOL 6926 1 PILOT 2 SEAL 3 SPECIAL TOOL 6926 2 INSTALLER 80468d54 DRIVE PLATE Fig 92 Rear Crankshaft
5. 16 Disconnect coolant reserve recovery hose 17 Remove accessory drive belts Refer to Group 7 Cooling System for procedure 18 Remove power steering pump and reservoir and set them aside 19 Hoist vehicle and remove right inner splash shield 20 Drain engine oil 21 Remove front wheels 22 Remove axle shafts Refer to Group 3 Differ ential and Driveline for procedure 23 Disconnect exhaust system from manifold 24 Disconnect the downstream oxygen sensor connector 25 Remove lower engine torque strut 26 Remove structural collar Refer to procedure in this section 27 Lower vehicle and remove A C compressor 28 Raise vehicle enough to allow engine dolly and cradle Special Tools 6135 and 6710 to be installed under vehicle 29 Loosen engine support posts to allow move ment for positioning onto engine locating holes and flange on the engine bedplate Lower vehicle and position cradle until the engine is resting on support posts Fig 26 Tighten mounts to cradle frame This will keep support posts from moving when removing or installing engine and transmission 30 Install safety straps around the engine to cra dle Fig 26 Tighten straps and lock them into posi tion WARNING Safety straps MUST be used PL 31 Raise vehicle enough to see if straps are tight enough to hold cradle assembly to engine 32 Lower vehicle so weight of the engine and transmission ONLY is on the cradle asse
6. CYLINDER COMBUSTION PRESSURE ENGINE DIAGNOSIS MECHANICAL 12 LEAKAGE TEST oag rea inata Baer 9 DIAGNOSIS AND TESTING GENERAL INFORMATION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance These malfunctions may be dassified as either mechanical Lego a strange noise or performance e g engine idles rough and stalls Refer to the Service Diagnosis Mechanical Chart and the Service Diagnosis Performance Chart for possible causes and corrections of malfunctions Refer to Group 14 Fuel System for the fuel system diag nosis Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts Information concerning additional tests and diagno sis is provided within the following Cylinder Compression Pressure Test Cylinder Combustion Pressure Leakage Test Engine Cylinder Head Gasket Failure Diagnosis Intake Manifold Leakage Diagnosis INTAKE MANIFOLD LEAKAGE DIAGNOSIS An intake manifold air leak is characterized by lower than normal manifold vacuum Also one or more cylinders may not be functioning WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN DO NOT WEAR LOOSE CLOTHING 1 Start the engine 2 Spray a small stream of water Spray Bott
7. Continued INSPECTING CYLINDER HEAD Check cylinder head for flatness with a straight edge Cylinder head must be flat within 0 1 mm 0 004 in Fig 127 9409 63 Fig 128 Checking Oil Pump Cover Flatness 1 OIL PUMP BODY 2 OIL PUMP COVER 3 OUTER ROTOR 9509 70 4 INNER ROTOR Fig 127 Checking Cylinder Head Flatness 1 FEELER GAUGE 2 STRAIGHT EDGE INSPECTING CAMSHAFT JOURNALS Inspect cylinder head camshaft bearings for wear Check the camshaft journals for scratches and worn areas If light scratches are present they may be removed with 400 grit sand paper If deep scratches are present replace the camshaft and check the cyl inder head for damage Replace the cylinder head if worn or damaged Check the lobes for pitting and wear If the lobes show signs of wear check the cor responding rocker arm roller for wear or damage Replace rocker arm hydraulic lash adjuster if worn or damaged If lobes show signs of pitting on the nose flank or base circle replace the camshaft OIL PUMP 1 Clean all parts thoroughly Mating surface of the oil pump should be smooth Replace pump cover if scratched or grooved 2 Lay a straightedge across the pump cover sur face Fig 128 If a 0 076 mm 0 003 inch feeler gauge can be inserted between cover and straight edge cover should be replaced 3 Measure thickness and diameter of outer rotor If outer rotor thickness measures 7 64 mm 0 301 inch
8. Fig 60 Cylinder Head Tightening Sequence 13 Install ignition coil and spark plug cables Connect coil electrical connector 14 Install intake manifold Refer to procedure in this section 15 Install upper radiator hose 16 Install ground wire to cylinder head 17 Install coolant recovery container 18 Connect fuel line to fuel rail 19 Install rear timing belt cover camshaft sprocket and timing belt tensioner and timing belt Refer to procedures in this section 20 Install front timing belt cover 21 Install engine mount bracket 22 Position engine and install right side engine mount to engine mount bracket bolt Tighten bolt to 118 N m 87 ft Ibs Remove jack from beneath engine 23 Install power steering pump assembly 24 Install power steering hose support clip and ground strap to engine mount bracket 25 Install upper torque strut 26 Raise vehicle 27 Install lower torque strut 28 Install crankshaft damper 29 Install accessory drive belts Refer to Group 7 Cooling System Accessory Drive Belt for procedure 30 Install right side splash shield and front wheel 31 Install exhaust pipe to exhaust manifold flange 32 Lower vehicle and fill cooling system Refer to Group 7 Cooling System for procedure 33 Connect negative cable to battery 34 Perform camshaft and crankshaft timing relearn procedure as follows e Connect the DRB scan tool to the data link diag
9. Ibs e Step 2 Install collar to transaxle bolts and tighten to 108 N m 80 ft Ibs e Step 3 Final torque the collar to oil pan bolts to 54 N m 40 ft Ibs 2 Lower vehicle ENGINE ASSEMBLY REMOVAL 1 Perform fuel pressure release procedure Refer to Group 14 Fuel System for procedure Remove fuel line to fuel rail 2 Disconnect and remove battery and tray 3 Drain cooling system Refer to Group 7 Cooling System for procedure 9 26 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued 4 Discharge air conditioning system if equipped Refer to Group 24 Heating and Air Conditioning for procedure 5 Disconnect the following air intake duct at intake manifold throttle cables electrical connectors from throttle body and air cleaner housing 6 Remove air cleaner housing assembly 7 Remove upper radiator hose and fan module Refer to Group 7 Cooling System for procedure 8 Remove lower radiator hose 9 Disconnect automatic transmission cooler lines and plug if equipped 10 Disconnect shift linkage electrical connectors and clutch cable if equipped with manual transaxle 11 Disconnect engine wiring harness 12 Disconnect positive cable from Power Distri bution Center PDC and ground wire from vehicle body 13 Disconnect ground wire from the vehicle body to engine at the right side strut tower 14 Disconnect heater hoses 15 Disconnect vacuum hose from brake booster
10. Install the main bear ing bedplate into engine block 6 Before installing the bolts oil threads with clean engine oil wipe off any excess oil 7 Install main bearing bedplate to engine block bolts 11 17 and 20 finger tight Tighten these bolts down together until the bedplate contacts the cylin der block Fig 100 PL X INDICATES DOWEL LOCATION 80be4cb2 Fig 100 Main Bearing Caps Bedplate Torque Sequence 8 Install main bearing bedplate to engine block bolts 1 10 and torque each bolt to 81 N m 60 ft Ibs in sequence shown in Fig 100 9 Install main bearing bedplate to engine block bolts 11 20 with baffle studs in positions 12 13 and 16 and torque each bolt to 34 N m 25 ft Ibs in sequence shown in Fig 100 10 After the main bearing bedplate is installed check the crankshaft turning torque The turning torque should not exceed 5 6 Nm 50 in Ibs 11 If crankshaft end play is to be checked refer to service procedures in this section 12 Install connecting rod bearings and caps Install new connecting rod bolts and tighten to 27 N m 20 ft Ibs plus 1 4 turn 13 Install oil pump and crankshaft front oil seal 14 Install oil pick up tube and oil pan Refer to procedure in the section 15 Install oil filter adapter and filter 16 Install lower torque strut air conditioning compressor mounting bracket to engine Fig 95 PL REMOVAL AND INSTALLATION Continu
11. LEV M8 Nut 28 M10 Bolt 54 M12 Bolt 95 70 Exhaust Manifold Support 54 40 Bracket ULEV Engine Torque Strut Bracket to Engine Bolts gt oO D 61 oO Powertrain Bending Strut Front Long Bolts Short Bolts Oil Pump Cover Plate Bolts Oil Pump Pick up Tube Bolt Oil Pump Relief Valve Cap PCV Valve _ Wu Rocker Arm Shaft Bolts Spark Plugs Timing Belt Cover Bolts Timing Belt Tensioner Assembly Bolts Water Pump Bolts 9 72 2 0L SOHC ENGINE Hi mii PL SPECIAL TOOLS 2 0L SOHC ENGINE Camshaft Seal Remover C 4679 A Puller 1026 Camshaft Seal Installer MD 998306 5 Crankshaft Damper Removal Insert 6827 A Ss Camshaft Sprocket Remover Installer C 4687 Camshaft Sprocket Remover Installer Adapter C 4687 1 Spring Compressor Adapter 6779 PL 2 0L SOHC ENGINE 9 73 SPECIAL TOOLS Continued Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Remover Insert C 4685 C2 801168ta Crankshaft Sprocket Installer 6792 Cylinder Bore Indicator C 119 amp N dech 7 3011692c Rear Crankshaft Seal Guide and Installer 6926 1 and 6926 2 Front Crankshaft Seal Remover 6771 SS Se Connecting Rod Guides 8189 Front Crankshaft Seal Installer 6780 9 74 2 0L SOHC ENGINE SPECIAL TOOLS Continued Post Kit Engine Cradle 6848 80114420 Dial Indicator C 3339 Driver Handle C 4171 Valve Spring Tester C 647
12. Refer to procedure in this section tightening sequence PL REMOVAL AND INSTALLATION Continued 80bbdad4 Fig 25 Left Mount Through Bolt 1 MOUNT BRACKET 2 BOLT 3 MOUNT 8 Install lower engine torque strut Refer to pro cedure in this section 9 Connect exhaust system to manifold Refer to Group 11 Exhaust System for procedure and torque specifications 10 Connect the downstream oxygen sensor 11 Install A C compressor and hoses Refer to Group 24 Heater and Air Conditioning for procedure 12 Install accessory drive belts Refer to Group 7 Cooling System Accessory Drive Section for belt ten sion adjustment 13 Install inner splash shield 14 Install wheels and lower vehicle 15 Install power steering pump and reservoir Refer to Group 7 Cooling System Accessory Drive Section for belt tension adjustment 16 Manual Transmission Connect clutch cable reverse light electrical connector and shift linkages Refer to Group 6 Clutch 17 Automatic Transmission Connect shifter kickdown linkage and cooler lines Refer to Group 21 Transaxle for procedures 18 Connect fuel line and heater hoses 19 Install all ground straps Connect engine wiring harness Refer to Group 8 Electrical for procedure 20 Install lower radiator hose fan module and upper radiator hose Refer to Group 7 Cooling Sys tem for procedures 21 Fill cooling system Refer to Group 7 Cooling S
13. carefully remove spark plug tube seals Care should be taken not to damage cylinder head cover sealing surfaces INSTALLATION 1 Clean all sealing surfaces PL REMOVAL AND INSTALLATION Continued 80bc4071 Fig 44 Spark Plug Tube Seal Installation 1 SPECIAL TOOL MB 998306 2 SPARK PLUG TUBE SEAL NOTE Position seal with the concave side facing the installation tool 2 Install seals using Special Tool MB 998306 Only hand pressure on tool is needed to install new seals 3 Install cylinder head cover Refer to procedures in this section SPARK PLUG TUBE 1 Remove cylinder head cover Refer to procedure in this section 2 Using locking pliers remove the tube from the cylinder head Fig 45 Discard old tube 3 Clean area around spark plug with Mopar parts cleaner or equivalent 4 Apply Mopar Stud and Bearing Mount or equivalent to a new tube approximately 1 mm from the end in a 3 mm wide area 5 Install sealer end of tube into the cylinder head Then carefully install the tube using a hard wood block and mallet until the tube is seated into the bottom of the bore 6 Install cylinder head cover Refer to procedure in this section 2 0L SOHC ENGINE 9 33 Fig 45 Spark Plug Tube Removal 1 LOCKING PLIERS 2 SPARK PLUG TUBE CAM SHAFT NOTE TO REMOVE CAMSHAFT THE CYLINDER HEAD MUST BE REMOVED REMOVAL 1 Perform fuel system pressure rel
14. tance Replace parts as necessary Refer to Group 8D Ignition System 7 Check fuel pump pressure at idle and different RPM ranges Refer to Group 14 Fuel System for specifications 8 The air filter elements should be replaced as specified in Group 0 Lubrication and Maintenance 9 Inspect crankcase ventilation system Refer to Group 25 Emission Control Systems 10 Road test vehicle as a final test HONING CYLINDER BORES 1 Used carefully the cylinder bore resizing hone recommended tool C 823 or equivalent equipped with 220 grit stones is the best tool for this honing procedure In addition to deglazing it will reduce taper and out of round as well as removing light scuffing scoring or scratches Usually a few strokes 9 4 ENGINE GENERAL INFORMATION Continued will clean up a bore and maintain the required lim its 2 Deglazing of the cylinder walls may be done using a cylinder surfacing hone recommended tool C 3501 or equivalent equipped with 280 grit stones if the cylinder bore is straight and round 20 60 strokes depending on the bore condition will be suf ficient to provide a satisfactory surface Inspect cyl inder walls after each 20 strokes using a light honing oil Do not use engine or transmission oil mineral spirits or kerosene 3 Honing should be done by moving the hone up and down fast enough to get a cross hatch pattern When hone marks intersect at 50 60 degrees the cross hatch angle is
15. 0 38 mm 0 005 0 015 in Wear Limit 0 40 mm 0 016 in Weight Total Less 543 grams Bearing 1 20 Ibs Crankshaft Connecting Rod Journal Diameter 1 8894 1 8900 in Ring Side Clearance Compression Rings Bearing Clearance Side Clearance Main Bearing Journal Diameter 2 0469 2 0475 in Journal Out of Round 0 0035 mm Max 0 0001 in Journal Taper Max Wear Limit 0 37 mm 0 015 in Main Bearing Diametrical 0 022 0 062 mm Clearance 0 0008 0 0024 in 47 9924 48 0076 mm 51 9924 52 0076 mm 0 0038 mm End Play 0 09 0 24 mm onen DESCRIPTION 2 0L SOHC ENGINE 9 69 SPECIFICATION Rocker Arm Shaft Rocker Arm Shaft Diameter 19 966 19 984 mm 0 7861 0 7868 in Rocker Arm Shaft Retainers Intake Width Exhaust Width 1 amp 5 Exhaust Width 2 3 and 28 43 28 49 mm 1 1193 1 1217 in 29 15 29 25 mm 1 1477 1 1516 in 40 40 40 50 mm 1 5906 1 5945 in Rocker Arm Hydraulic Lash Adjuster Rocker Arm Inside Diameter Rocker Arm Shaft Clearance Body Diameter Plunger Travel Minimum Dry Dry Lash Intake Dry Lash Exhaust Rocker Arm Ratio 20 00 20 02 mm 0 787 0 788 in 0 016 0 054 mm 0 0006 0 0021 in 22 949 22 962 mm 0 9035 0 9040 in 2 2 mm 0 087 in 1 17 mm 0 046 in 1 28 mm 0 050 in 1 4 to 1 Cylinder Head Camshaft Bearing Diameter Journal No 1 Journal No 2 Journal No 3 Journal No 4 41 20 41 221 mm 1
16. 1 Raise vehicle on hoist 2 Remove right side splash shield 3 Remove bolts attaching lower strut to cross member and strut bracket Fig 10 4 Remove lower torque strut INSTALLATION 1 Position lower torque strut into mounting loca tions 2 Install mounting bolts and perform torque strut adjustment procedure 3 Install splash shield and lower vehicle TORQUE STRUT ADJUSTMENT The upper and lower torque struts need to be adjusted together to assure proper engine positioning and engine mount loading Whenever a torque strut bolt s is loosened this procedure must be performed 1 Loosen the upper and lower torque strut attaching bolt at the suspension crossmember and shock tower bracket 2 The engine position may now be adjusted by positioning a suitable floor jack on the forward edge of the transmission bell housing Fig 11 NOTE The floor jack must be positioned as shown in Fig 11 to prevent minimal upward lifting of the engine BL 2 0L SOHC ENGINE 9 21 REMOVAL AND INSTALLATION Continued Ss KA PA a Bs a 6 80bbc30a Fig 10 Torque Struts Upper and Lower 1 BOLTS 5 CROSSMEMBER 2 ENGINE MOUNT BRACKET 6 LOWER TORQUE STRUT 3 TORQUE STRUT BRACKET 7 BOLTS 4 UPPER TORQUE STRUT 8 RIGHT FENDER 3 Carefully apply upward force allowing the upper engine to rotate rearward until the distance between the center of the rearmost attaching
17. 622 1 6228 in 41 60 41 62 mm 1 637 1 638 in 42 0 42 02 mm 1 653 1 654 in 42 4 42 42 mm 1 669 1 670 in Journal No 5 42 8 42 82 mm 1 685 1 6858 in Journal Diameter Camshaft 41 128 41 147 mm 1 619 1 6199 in 41 528 41 547 mm 1 634 1 635 in 9 70 2 0L SOHC ENGINE SPECIFICATIONS Continued SPECIFICATION 41 928 41 947 mm 1 650 1 651 in 42 328 42 374 mm 1 666 1 668 in 42 728 42 747 mm 1 682 1 6829 in 0 053 0 093 mm 0 0027 0 003 in 0 12 mm 0 05 0 39 mm 7 2 mm 0 283 in 7 03 mm 0 277 in Exhaust Valve Timing Opens 8800 Duration Intake Valve Timing Closes ABDC 41 1 Opens ATDC Duration 207 2 Valve Overlap Al readings in crankshaft degrees at 0 5 mm 0 019 in of valve lift Cylinder Head Material Cast Aluminum Gasket Thickness 1 15 mm Compressed 0 045 in 33 mm 1 299 in 28 mm 0 05 mm 0 002 in Valve Seat Width Intake 0 9 1 3 mm and Exhaust 0 035 0 051 in DESCRIPTION No 3 No 4 No 5 Bearing Clearance Diametrical Bearing Clearance Max allowable End Play Lift Zero Lash Exhaust Seat Diameter Intake Seat Diameter Exhaust Runout Max PL DESCRIPTION SPECIFICATION Service Limit Intake 2 0 mm TL een Service Limit Exhaust 2 5 mm Diameter D 5 975 6 000 mm a 0 235 0 236 in Guide Bore Diameter 11 0 11 02 mm Guide Height spring seat 13 25 13 75 mm to guide tip 0 52
18. For specifications refer to Engine Specifications in this section The valve tip chamfer may need to be reground to prevent seal damage when the valve is installed CLEANING Clean all valve guides valves and valve spring assemblies thoroughly with suitable cleaning solution before reassembling VALVE INSTALLATION 1 Coat valve stems with clean engine oil and insert in cylinder head 2 Install new valve stem seals on all valves using a valve stem seal tool Fig 124 The valve stem seals should be pushed firmly and squarely over valve guide PL B A 9509 51 Fig 123 Spring Installed Height and Valve Tip to Spring Seat Dimensions 1 GARTER SPRING 2 VALVE SPRING SEAT 3 CYLINDER HEAD SURFACE CAUTION If oversize valves are used there is only one oversize valve available The same stem seal is used on both the standard and oversize valve Fig 124 Valve Stem Oil Seal Tool 1 VALVE SEAL TOOL 2 VALVE STEM 3 Install valve springs and retainers Compress valve springs only enough to install locks taking care not to misalign the direction of compression Nicked valve stems may result from misalignment of the valve spring compressor CAUTION When depressing the valve spring retainers with valve spring compressor the locks can become dislocated Check to make sure both locks are in their correct location after removing tool 4 Check the valve spring installed he
19. Seal installation 1 SPECIAL TOOL 6926 2 INSTALLER REMOVAL 1 Remove transaxle Refer to Group 21 Tran saxle for procedure 2 Remove drive plate attaching bolts Fig 93 3 Remove drive plate Fig 93 INSTALLATION 1 Position drive plate on crankshaft Fig 93 2 Apply Mopar Lock amp Seal Adhesive to drive plate bolt threads 3 Install drive plate bolts and tighten to 95 N m 70 ft Ibs Fig 93 4 Install transaxle Refer to Group 21 Transaxle for procedure 80b89842 Fig 93 Drive Plate 1 ADAPTOR PLATE 2 BOLT 3 BOLT QTY 8 4 DRIVE PLATE 9 52 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued CRANKSHAFT PL 80bceagd Fig 94 Crankshaft and Components 8 OIL FILTER ADAPTER 9 CRANKSHAFT POSITION SENSOR CPS 10 MAIN BEARING CAP BED PLATE ASSEMBLY 11 CONNECTING ROD BEARINGS 12 PISTON AND CONNECTING ROD ASSEMBLY 1 OIL PASSAGE O RING 2 SEAL 3 UPPER BEARING GROOVED 4 THRUST BEARINGS 5 BOLT 6 O RING 13 SEAL 7 NIPPLE REMOVAL 10 Remove lower torque strut air conditioning 1 Remove engine assembly Refer to procedure in this section 2 Remove structural collar from oil pan to tran saxle housing 3 Separate transaxle from engine 4 Remove drive plate flywheel 5 Remove crankshaft rear oil seal Refer to pro cedure in this section 6 Mount engine on a suitable repair s
20. System 6 Remove exhaust pipe from manifold 7 Remove right front wheel 8 Remove right side splash shield 9 Remove generator belt Refer to Group 7 Cool ing System Accessory Drive Belts for procedure 10 Remove crankshaft damper Refer to proce dure in this section 11 Remove lower torque strut 12 Lower vehicle and remove upper torque strut 13 Remove ground strap and power steering hose support clip from engine mount bracket 14 Remove power steering pump assembly and set aside 15 Support engine from beneath with a suitable jack 16 Remove right side engine mount to bracket through bolt 17 Remove the lower engine mount bracket bolt Raise engine slightly and remove the upper engine mount bracket bolts 2 0L SOHC ENGINE 9 37 18 Remove engine mount bracket This procedure may require additional raising lowering of engine until bracket will clear engine components 19 Remove front timing belt cover 20 Rotate engine until timing marks are aligned 21 Remove timing belt and tensioner Refer to procedures in this section 22 Remove camshaft sprocket Refer to proce dures in this section 23 Remove rear timing belt cover 24 Disconnect fuel line at fuel rail 25 Remove coolant recovery container 26 Remove ground wire to cylinder head 27 Remove upper radiator hose 28 Remove intake manifold Refer to procedure in this section 29 Disconnect ignition coil elect
21. attaching holes are slightly oversize to compensate for manufacturing tolerances The mount has been set at the manufac turing plant for proper powertrain alignment There fore it is necessary to mark the position of the mount before the attaching bolts are loosened 7 Using a permanent ink marker or equivalent mark the position of engine mount to the body frame rail 8 Remove bolts attaching mount to body Fig 19 9 Remove mount between engine and body frame rail Mount removal may require engine position to be raised or lowered to allow mount removal clear ance 80bc4e9b Fig 18 Engine Mount To Bracket Bolt 1 BOLT 2 RIGHT ENGINE MOUNT 3 ENGINE MOUNT BRACKET INSTALLATION 1 Position mount into the original position on body frame rail Fig 19 9 24 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued 80bc4f05 Fig 19 Engine Mount Right 1 SNUBBER PAD 2 RIGHT ENGINE MOUNT 3 BOLTS NOTE Engine mount must be installed in the orig inal position on body frame rail If mount was not marked or frame rail was replaced perform the fol lowing procedure 2 Perform the following procedure if mount posi tion was not previously marked or the frame rail was replaced a Insert new mount loosely in frame rail b Align the four holes in the mount with the mat ing holes in the rail such that the holes are concen tric frame rail holes centered in the mount holes c Us
22. carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine Fig 97 All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation Bearing shells are available in standard and the following undersized 0 016 mm 0 0006 in 0 032 mm 0 0012 in 0 250 mm 0 010 in Never install an undersize bearing that will reduce clearance below specifications 9 54 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued INSTALLATION 1 Install the main bearing shells with the lubri cation groove in the cylinder block Install O ring into recess in the block Fig 98 9509 45 Fig 98 Installing Main Bearing Upper Shell 1 LUBRICATION GROOVES 2 O RING 3 OIL HOLES 2 Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots CAUTION Do Not get oil on the bedplate mating surface It will affect the sealer ability to seal the bedplate to cylinder block 3 Oil the bearings and journals and_ install crankshaft in cylinder block CAUTION Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine 4 Apply 1 5 2 0 mm 0 059 0 078 in bead of Mopar Bed Plate Sealant to cylinder block as shown in Fig 99 5 Install lower main bearings into main bearing cap bedplate Make certain the bearing tabs are seated into the bedplate slots
23. coil and spark plug cables Tighten ignition coil fasteners to 12 N m 105 in Ibs 13 Perform camshaft and crankshaft timing relearn procedure as follows e Connect the DRB scan tool to the data link diagnostic connector This connector is located in the passenger compartment at the lower edge of instrument panel near the steering column e Turn the ignition switch on and access the mis cellaneous screen e Select relearn cam crank option and follow directions on DRB screen ROCKER ARM HYDRAULIC LASH ADJUSTER REMOVAL 1 Remove cylinder head cover Refer to procedure in this section 2 Identify the rocker arm shaft assemblies before removal 3 Loosen the attaching fasteners Remove rocker arm shaft assemblies from cylinder head 4 Identify the rocker arms spacers and retainers for reassembly Disassemble the rocker arm assem blies by removing the attaching bolts from the shaft Fig 48 PL REMOVAL AND INSTALLATION Continued 9509 15 Fig 48 Rocker Arm Shaft Assemblies 1 EXHAUST ROCKER ARM ASSEMBLY 2 PLASTIC SHAFT SPACERS 3 INTAKE ROCKER ARM ASSEMBLY 4 ROCKER ARM SHAFT RETAINERS 5 Slide the rocker arms and spacers off the shaft Keep the spacers and rocker arms in the same loca tion for reassembly NOTE Inspect the rocker arm for scoring wear on the roller or damage to the rocker arm Fig 49 Replace if necessary Check the location where the rocker arms m
24. described in the Group 0 Lubrication and Mainte nance ENGINE 9 7 ENGINE OIL VISCOSITY GRADES 5W 30 Preferred 0 10 20 32 60 80 100 48 142 vn 0 16 27 38 Temperature range anticipated before next oil change 9400 9 Fig 10 Engine Oil Container Standard Notations TO CHANGE ENGINE OIL Run engine until achieving normal operating tem perature 1 Position the vehicle on a level surface and turn engine off 2 Hoist and support vehicle on safety stands Refer to Group 0 Lubrication and Maintenance for Hoisting and J acking Recommendations 3 Remove oil fill cap 4 Place a suitable drain pan under crankcase drain 5 Remove drain plug from crankcase and allow oil to drain into pan Inspect drain plug threads for stretching or other damage Replace drain plug and gasket if damaged 6 Install drain plug in crankcase 7 Lower vehicle and fill crankcase with specified type and amount of engine oil described in this sec tion 8 Install oil fill cap 9 Start engine and inspect for leaks 10 Stop engine and inspect oil level 9 8 ENGINE PL ENGINE DIAGNOSIS TABLE OF CONTENTS page page DIAGNOSIS AND TESTING LASH ADJUSTER TAPPET NOISE GENERAL INFORMATION 8 DIAGNOSIS ousar irice ro ee 9 INTAKE MANIFOLD LEAKAGE DIAGNOSIS 8 ENGINE OIL LEAK INSPECTION 9 CYLINDER COMPRESSION PRESSURE TEST 8 ENGINE DIAGNOSIS PERFORMANCE 11
25. further routing Rod bearing oil throw off lubricates the pistons from directed slots on the side of the connecting rod assemblies Camshaft and valve mechanisms are lubricated from a full length cylinder head oil gallery supplied from the crankcase main oil gallery 7 O RING 8 OIL PUMP BODY 9 FILTER 10 O RING 11 NIPPLE PRESSURE LUBRICATION Oil drawn up through the pickup tube is pressur ized by the pump and routed through the full flow fil ter to the main oil gallery running the length of the cylinder block A cylinder head restrictor integral to the cylinder head gasket provides increased oil flow to the main oil gallery Fig 2 MAIN ROD BEARINGS A diagonal hole in each bulkhead feeds oil to each main bearing Drilled passages within the crankshaft route oil from main bearing journals to connecting rod journals CAMSHAFT HYDRAULIC LASH ADJUSTERS A vertical hole at the number five bulkhead routes pressurized oil through a restrictor up into the cylin 9 18 2 0L SOHC ENGINE DESCRIPTION AND OPERATION Continued et N N N N Ge 9409 56 Fig 2 Engine Lubrication System SOHC der head The rocker shafts route oil to the rocker arms hydraulic lash adjuster assemblies SPLASH LUBRICATION Oil returning to the pan from pressurized compo nents supplies lubrication to the valve stems Cylin der bores and wrist pins are splash
26. lubricated from directed slots on the connecting rod thrust collars DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE 1 Remove oil pressure switch and install gauge assembly C 3292 with adaptor 2 Run engine until thermostat opens CAUTION If oil pressure is 0 at idle Do Not per form the 3000 RPM test in the next step 3 Oil Pressure Curb Idle 25 kPa 4 psi mini mum 3000 RPM 170 550 kPa 25 80 psi 4 If oil pressure is O at idle Shut off engine check for pressure relief valve stuck open a clogged oil pick up screen or a damaged oil pick up tube O ring SERVICE PROCEDURES CYLINDER BORE AND PISTON SIZING The cylinder walls should be checked for out of round and taper with recommended tool C 119 or equivalent Fig 3 The cylinder bore out of round PL and cylinder bore taper must within service limits Refer to Engine Specifications in this section If the cylinder walls are badly scuffed or scored the cylin der block should be rebored and honed and new pis tons and rings fitted Whatever type of boring equipment is used boring and honing operations should be closely coordinated with the fitting of pis tons and rings in order to maintain specified clear ances Refer to Honing Cylinder Bores in the Standard Service Procedures for procedures Measure the cylinder bore at three levels in direc tions A and B Fig 3 Top measurement should be 10 mm 3 8 inch down and bottom measurement should be 10
27. most satisfactory for proper seat ing of rings Fig 4 ae aes BET EZ Se Ar Ce ER SEE ER lt LT a SS bled KL Lie LoL CLT ZZ Dee d 2 e LiF ZZ EL AOE aT LL EL ZZ SS Ges SE COLL L L Z gt SLZ LZ Es Law 2 SE Ce SSCS ee De Ee 27 lt 7 SE Se SEE E SZ SUNG RN RER RR d N 9 PR652 Fig 4 Cylinder Bore Cross Hatch Pattern 1 CROSS HATCH PATTERN 4 A controlled hone motor speed between 200 300 RPM is necessary to obtain the proper cross hatch angle The number of up and down strokes per minute can be regulated to get the desired 50 60 degree angle Faster up and down strokes increase the cross hatch angle 5 After honing it is necessary that the block be cleaned again to remove all traces of abrasive CAUTION Ensure all abrasives are removed from engine parts after honing It is recommended that a solution of soap and hot water be used with a brush and the parts then thoroughly dried The bore can be considered clean when it can be wiped clean with a white cloth and cloth remains clean Oil the bores after cleaning to prevent rusting PL MEASURING WITH PLASTIGAGE 9509 60 Fig 5 Plastigage Placed in Lower Shell 1 PLASTIGAGE PLASTIGAGE METHOD Engine crankshaft bearing clearances can be deter mined by use of Plastigage or equivalent The follow ing is the recommended procedure for the use
28. of test pressure e Gradually apply air pressure from 1 psi to 2 5 psi maximum while applying soapy water at the sus pected source Adjust the regulator to the suitable test pressure that provides the best bubbles which will pinpoint the leak source If the oil leak is detected and identified repair per service manual procedures e If the leakage occurs at the crankshaft rear oil seal area refer to the section Inspection for Rear Seal Area Leak 6 If no leaks are detected turn off the air supply Remove the air hose all plugs and caps Install the PCV valve and CCV hose Proceed to next step 7 Clean the oil off the suspect oil leak area using a suitable solvent Drive the vehicle at various speeds approximately 24 km 15 miles Inspect the engine for signs of an oil leak by using a black light INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the PL engine a more involved inspection is necessary The following steps should be followed to help pinpoint the source of the leak If the leakage occurs at the crankshaft rear oil seal area 1 Disconnect the battery 2 Raise the vehicle 3 Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil Use a black light to check for the oil leak If a leak is present in this area remove transmission for further inspection a Circular spray pattern ge
29. set number one cylinder to TDC on the compression stroke e Remove the access plug from the outer timing belt cover Fig 67 e Check the timing mark on the camshaft sprocket it should align with the arrow on the rear belt cover Fig 68 REMOVAL TIMING BELT 1 Remove accessory drive belts Refer to Group 7 Cooling System for procedures 2 Raise vehicle on a hoist and remove right inner splash shield 3 Remove crankshaft damper bolt Remove damper using Special Tools 1026 three jaw puller and 6827 A insert Fig 69 4 Remove lower torque strut 5 Lower vehicle and place a jack under engine 6 Remove upper torque strut 7 Remove right engine mount to engine mount bracket through bolt 8 Remove power steering pump assembly and set aside 9 Remove engine mount bracket Fig 70 10 Remove front timing belt cover Fig 71 CAUTION Align camshaft and crankshaft timing marks before removing the timing belt by rotating the engine with the crankshaft 9 44 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued TEENE AENIL Fig 68 Camshaft Timing Marks 1 CAM SPROCKET TIMING MARK 2 ARROW ON REAR COVER 80387209 Fig 69 Crankshaft Damper Removal 1 SPECIAL TOOL 6827 A INSERT 2 SPECIAL TOOL 1026 THREE JAW PULLER 11 Insert a 8 mm Allen wrench into the hexagon opening located on the front of the belt tensioner pul ley Fig 72 Rotate the pulley counterclockwis
30. side of the engine 5 Pistons and connecting rods must be removed from top of cylinder block Rotate crankshaft so that each connecting rod is centered in cylinder bore 6 Remove connecting rod cap bolts Do not use old bolts if reinstalling connecting rod 7 To protect crankshaft journal and fractured rod surfaces install Special Tool 8189 connecting rod guides onto connecting rod Fig 110 Carefully push each piston and rod assembly out of cylinder bore CAUTION Care must be taken not to damage the fractured rod and cap joint surfaces as engine damage many occur 8 Remove Special Tool 8189 connecting rod guides and reinstall bearing cap on the mating rod NOTE Piston and rods are serviced as an assem bly PISTON RING REMOVAL 1 The identification mark on face of upper and intermediate piston rings must point toward piston crown 2 Using a suitable ring expander remove upper and intermediate piston rings Fig 111 3 Remove the upper oil ring side rail lower oil ring side rail and then oil ring expander from piston 4 Clean ring grooves of any carbon deposits PISTON RINGS INSTALLATION 1 Install rings with manufacturers identification mark facing up to the top of the piston Fig 112 PL as N 80a 830 Fig 110 Connecting Rod Guides Typical 1 SPECIAL TOOL 8189 CONNECTING ROD GUIDES 9409 182 Fig 111 Piston Rings Removing and Installing CAUTION In
31. sure not to damage the main bearings or journals when removing the crankshaft CRANKSHAFT MAIN BEARINGS LOCATION The crankshaft is supported in five main bearings All upper bearing shells in the crankcase have oil grooves All lower bearing shells installed in the bed plate main bearing cap are plain Crankshaft end 2 0L SOHC ENGINE 9 53 play is controlled by a flanged bearing on the number three main bearing journal Fig 97 NOTE The upper and lower main Bearing shells are Not interchangeable The lower shells have a revised tab to prevent improper installation 5 9209 116 Fig 97 Main Bearing Identification 1 OIL GROOVES 2 UPPER BEARINGS 3 LOWER BEARINGS 4 OIL HOLES CRANKSHAFT MAIN JOURNALS INSPECTION The crankshaft journals should be checked for excessive wear taper and scoring Limits of taper or out of round on any crankshaft journals should be held to 0 025 mm 0 001 in J ournal grinding should not exceed 0 305 mm 0 012 in under the standard journal diameter DO NOT grind thrust faces of Number 3 main bearing DO NOT nick crank pin or bearing fillets After grinding remove rough edges from crankshaft oil holes and clean out all passages CAUTION With the nodular cast iron crankshafts used it is important that the final paper or cloth pol ish after any journal regrind be in the same direc tion as normal rotation in the engine Upper and lower Number 3 bearing halves are flanged to
32. that no piston to valve contact occurs upon installation of cylinder head in the event of camshaft rotation 5 Position the cylinder head onto the cylinder block Make sure the cylinder head seats fully over the locating dowels 6 Before installing cylinder head bolts the threads should be oiled with engine oil The 4 shorter bolts 164 mm 6 45 in are to be installed in posi tions 7 8 9 and 10 Fig 60 7 Tighten the cylinder head bolts in the sequence shown in Fig 60 Using the 4 step torque method tighten according to the following values 2 0L SOHC ENGINE 9 39 80af61d9 Fig 58 Proper Tool Usage for Surface Preparation 1 ABRASIVE PAD 2 3M ROLOC BRISTLE DISC 3 PLASTIC WOOD SCRAPER ER lt P ag a 80ae0e97 Fig 59 Crankshaft Sprocket Position 1 TDC MARK e First All to 34 N m 25 ft Ibs e Second All to 68 N m 50 ft Ibs e Third All to 68 N m 50 ft Ibs e Fourth Turn an additional 1 4 Turn Do not use a torque wrench for this step 8 Install cylinder head cover 9 Install heater hose to thermostat housing con nector 10 Install heater tube to cylinder head attaching fasteners 11 Connect cam sensor and coolant temperature electrical connectors 12 Connect Crankcase Closed Ventilation CCV hose to cylinder head cover 9 40 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued 80bc4ch0
33. to both intake and exhaust valve springs e Valve Closed Nominal Tension 70 Ibs 39 8 mm 1 57 in e Valve Closed Nominal Tension 160 Ibs 32 6 mm 1 28 in 2 Verify springs are not distorted with a steel square and surface plate check springs from both ends If the spring is more than 1 5 mm 1 16 in out of square install a new spring 9 61 2 0L SOHC ENGINE Z 9509 79 Fig 120 Valve Spring Testing 1 TORQUE WRENCH 2 VALVE SPRING TESTER REFACING VALVES AND VALVE SEATS 1 The intake and exhaust valve seats and valve face have a 45 degree angle 2 Inspect the remaining margin after the valves are refaced Fig 121 Intake valves with less than 0 95 mm 1 32 in margin and exhaust valves with less than 1 05 mm 3 64 in margin should be dis carded k 9409 78 Fig 121 Intake and Exhaust Valve Refacing 1 VALVE FACE 2 VALVE MARGIN 3 When refacing valve seats it is important that the correct size valve guide pilot be used for reseat ing stones A true and complete surface must be obtained For specifications refer to Engine Specifi cations in this section 4 Measure the concentricity of valve seat and valve guide using a valve seat runout dial indicator Total runout should not exceed 0 051 mm 0 002 in total indicator reading 5 Inspect the valve seat with Prussian blue to determine where the valve contacts the seat To do this
34. to engine oil Moisture in the air causes the material to cure This material is available in three ounce tubes and has a shelf life of one year After one year this material will not properly cure Always ENGINE 9 1 page 2 0L SOHC ENGINE cicis sa sun ea 15 page HONING CYLINDER BORES 3 MEASURING WITH PLASTIGAGE 4 REPAIR OF DAMAGED OR WORN THREADS 5 HYDROSTATIC LOCKED ENGINE 5 CHECKING ENGINE OIL LEVEL 6 ENGINE OIL SERVICE 2 222 7 inspect the package for the expiration date before use MOPAR ATF RTV Mopar ATF RTV is a Specifically designed black silicone rubber RTV that retains adhesion and seal ing properties to seal components exposed to auto matic transmission fluid engine coolants and moisture This material is available in three ounce tubes and has a shelf life of one year After one year this material will not properly cure Always inspect the package for the expiration date before use MOPAR GASKET MAKER Mopar Gasket Maker is an anaerobic type gasket material The material cures in the absence of air when squeezed between two metallic surfaces It will not cure if left in the uncovered tube The anaerobic material is for use between two machined surfaces Do not use on flexible metal flanges MOPAR BED PLATE SEALANT Mopar Bed Plate Sealant is a unique green in color anaerobic type gasket material that is specially made to seal t
35. 1 0 541 in Exhaust Head Diameter Intake 32 12 33 37 mm Head Diameter Exhaust 28 57 28 83 mm 1 124 1 135 in Intake 1 15 1 48 mm Service Limit 0 95 mm 1 475 1 805 mm 0 058 0 071 in Service Limit 1 05 mm 3 64 in Valve Length Overall Intake 114 69 115 19 mm 4 515 4 535 in 116 94 117 44 mm 4 603 4 623 in Intake 45 01 46 07 mm 43 51 44 57 mm 1 71 1 75 in Intake 5 934 5 952 mm 0 2337 0 2344 in PL SPECIFICATIONS Continued Exhaust 5 906 5 924 mm EEE ae Intake 0 048 0 066 mm Max Allowable 0 076 mm Service Limit 0 25 mm 0 0736 0 094 mm Max Allowable 0 101 mm Service Limit 0 25 mm Valve Springs Free Length Approx 46 75 mm Nominal Force Valve 331 N 39 8 mm Nominal Force Valve 711 N 32 6 mm Installed Height 40 18 mm Ft Lb 3 Camshaft Sensor 85 Pick up Bolts S Camshaft Sprocket Bolt Connecting Rod 27 4 20 4 Cap Bolts turn turn Refer to Procedure Exhaust TORQUE DESCRIPTION Structural Collar Bolts Crankshaft Main Bearing Cap Bedplate MB8 Bolts 34 25 M11 Bolts 81 60 Crankshaft Damper Cylinder Head Bolts Cylinder Head Cover Bolts Refer to Procedure Bais 2 0L SOHC ENGINE 9 71 DESCRIPTION Ft In bad ie Dive Pate Gana 5 m Engine Mount Bracket a ae Right Bolts Engine Mounting Refer to Procedure Exhaust Manifold to 23 200 Cylinder Head Bolts Exhaust Manifold Support Bracket Federal and
36. 3 Inspect manifolds for cracks or distortion Replace manifold if necessary 2 0L SOHC ENGINE 9 63 CYLINDER HEAD AND CAMSHAFT JOURNALS CLEANING Remove all gasket material from cylinder head Be careful not to gouge or scratch the aluminum head sealing surface Clean all engine oil passages To ensure engine gasket sealing proper surface preparation must be performed especially with the use of aluminum engine components and multi layer steel cylinder head gaskets Never use the following to clean aluminum gasket surfaces e Metal scraper e Abrasive pad or paper to clean cylinder block and head e High speed power tool with an abrasive pad or a wire brush Fig 126 NOTE Multi Layer Steel MLS head gaskets require a scratch free sealing surface Only use the following for cleaning gasket surfaces e Solvent or a commercially available gasket remover e Plastic or wood scraper Fig 126 e Drill motor with 3M Roloc Bristle Disc white or yellow Fig 126 CAUTION Excessive pressure or high RPM can damage the sealing surfaces The mild white 120 grit bristle disc is recommended If necessary the medium yellow 80 grit bristle disc may be used on cast iron surfaces with care 80af61 dg Fig 126 Proper Tool Usage For Surface Preparation 1 ABRASIVE PAD 2 3M ROLOC BRISTLE DISC 3 PLASTIC WOOD SCRAPER 9 64 2 0L SOHC ENGINE Hi i PL CLEANING AND INSPECTION
37. AME RAIL INSTALLATION 1 Install mount and attaching bolts Fig 16 or Fig 17 Tighten bolts to 68 N m 50 ft Ibs 2 Install engine mount bracket to body frame rail and tighten fasteners to 28 N m 250 in Ibs Fig 15 3 Position engine transaxle for installation of through bolt Install and tighten through bolt to 118 N m 87 ft Ibs Fig 14 4 Remove jack from under transaxle 5 Install through bolt access plug at left side outer frame rail 6 Install left splash shield and wheel 7 Connect transaxle shift cable to engine mount and transaxle linkage 8 Install battery tray and battery PL REMOVAL AND INSTALLATION Continued 80bbdad9 Fig 16 Left Mount Automatic Transaxle 1 MOUNT 2 TRANSAXLE 80bbdad8 Fig 17 Left Mount Manual Transaxle 1 MOUNT 2 TRANSAXLE 9 Install air cleaner assembly Fig 13 10 Lower vehicle 2 0L SOHC ENGINE 9 23 ENGINE MOUNT RIGHT REMOVAL 1 Remove accessory drive belts Refer to Group 7 Cooling System for procedure 2 Remove crankshaft damper Refer to procedure in this section 3 Remove upper and lower engine torque struts Refer to procedure in this section 4 Support engine with a suitable jack 5 Remove bolt access cover and bolt attaching the right engine mount to mount bracket Fig 18 6 Remove engine mount bracket Refer to proce dure in this section NOTE The right engine mount
38. AR COVER 2 Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover Fig 73 3 Move crankshaft to 1 2 mark before TDC Fig 75 for belt installation 80ae0e98 Fig 75 Adjusting Crankshaft Sprocket for Timing Belt Installation 1 TDC REFERENCE MARK 2 1 2 NOTCH LOCATION 3 TDC MARK 4 Install timing belt Starting at the crankshaft go around the water pump sprocket and then around the camshaft sprocket 5 Move crankshaft sprocket to TDC to take up belt slack 6 Remove the pin or 1 8 or 3 mm Allen wrench from belt tensioner 7 Rotate crankshaft 2 revolutions and check the alignment of the timing marks Fig 76 8 Install front timing belt cover 9 Install engine mount bracket 9 46 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued N eS Ry N S GER CVE ORO 80add405 Fig 76 Crankshaft and Camshaft Timing 1 CAMSHAFT TIMING MARKS 2 CRANKSHAFT AT TDC 10 Install right engine mount to engine mount bracket through bolt 11 Remove jack from under engine 12 Install upper torque strut 13 Install power steering pump assembly 14 Raise vehicle and install lower torque strut 15 Install crankshaft damper using M12 1 75 x 150 mm bolt washer thrust bearing and nut from Special Tool 6792 Install crankshaft damper bolt and tighten to 142 N m 100 ft Ibs Fig 77 16 Install
39. ATION 1 Make sure all surfaces are clean and free of oil and dirt 2 Apply Mopar Gasket Maker to oil pump as shown in Fig 105 Install oil ring into oil pump body discharge passage 3 Prime oil pump before installation 4 Align oil pump rotor flats with flats on crank shaft as you install the oil pump to the block NOTE Front crankshaft seal MUST be out of pump to align or damage may result 5 Torque all oil pump attaching bolts to 28 N m 250 in Ibs 6 Install new front crankshaft seal using Special Tool 6780 Fig 106 7 Install crankshaft sprocket using Special Tool 6792 Fig 107 80a53b24 Fig 104 Oil Pump and Tube 1 O RING 2 OIL FILTER ADAPTER 3 OIL PAN GASKET 4 OIL PAN 5 OIL PICK UP TUBE 6 DRAIN PLUG 7 O RING 8 OIL PUMP BODY 9 FILTER 10 O RING 11 NIPPLE PL REMOVAL AND INSTALLATION Continued 9509 254 Fig 105 Oil Pump Sealing 1 APPLY GASKET MAKER TO OIL PUMP BODY FLANGE 2 O RING 9409 187 Fig 106 Front Crankshaft Seal Installation 1 PROTECTOR 2 SEAL 3 SPECIAL TOOL 6780 1 4 INSTALLER 9 57 2 0L SOHC ENGINE 4 Fig 107 Crankshaft Sprocket Insiallation 1 SPECIAL TOOL 6792 2 TIGHTEN NUT TO INSTALL 9509 287 8 Install oil pick up tube and oil pan 9 Install rear timing belt cover and camshaft sprocket 10 Install timing belt t
40. Disc white or yellow Fig 1 CAUTION Excessive pressure or high RPM can damage the sealing surfaces The mild white 120 grit bristle disc is recommended If necessary the medium yellow 80 grit bristle disc may be used on cast iron surfaces with care 80af61d9 Fig 1 Proper Tool Usage For Surface Preparation 1 ABRASIVE PAD 2 3M ROLOC BRISTLE DISC 3 PLASTIC WOOD SCRAPER CRANKSHAFT DAMPER BOLT ACCESS PLUG An access plug is located in the right splash shield Fig 2 Remove the plug and insert the proper size socket extension and ratchet when crankshaft rota tion is necessary ENGINE CORE PLUGS REMOVAL Using a blunt tool such as a drift or a screwdriver and a hammer strike the bottom edge of the cup plug Fig 3 With the cup plug rotated grasp firmly with pliers or other suitable tool and remove plug Fig 3 PL GENERAL INFORMATION Continued 80b04103 Fig 2 Access Plug 1 CRANKSHAFT BOLT ACCESS PLUG 2 RIGHT MOUNT BOLT ACCESS PLUG 3 FASCIA 4 SPLASH SHIELD CAUTION Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems INSTALLATION Thoroughly clean all debris rust from inside of cup plug hole in cylinder block or head Be sure to remove old sealer Lightly coat inside of cup plug hole with Mopar Stud and Bearing Mount Adhesive Make certain the new plug is cleaned of all oil o
41. ER 34 VALVE SEALS AND SPRINGS IN VEHICLE 36 CYLINDER HEAD 4 2 cad ei ea dee ba eee as 37 CRANKSHAFT DAMPER 2 22 40 TIMING BELT COVERS 41 DESCRIPTION AND OPERATION ENGINE IDENTIFICATION The engine identification number is located on the left rear of the cylinder block bedplate Fig 1 ENGINE COMPONENTS CYLINDER BLOCK AND BEDPLATE ASSEMBLY A partial open deck is used for cooling and weight reduction with water pump molded into the block Nominal wall thickness is 4 mm The bedplate incor porates main bearing caps The rear oil seal retainer is integral with the block 2 0L SOHC ENGINE 9 15 page TIMING BEEF sg 0 00000 43 TIMING BELTITENSGIONER 46 CAMSHAFT OIL SEAL aoaaa 46 OIE RAN A ci ee ete a Meee en 47 CRANKSHAFT OIL SEAL FRONT 48 CRANKSHAFT OIL SEAL REAR 50 DRIVE PLATE a ccna 02804 nate aang aa 51 CRANKSHAFT 2 2 22 onen 52 OIL FILTER ADAPTER 2 2 22 55 OIL FILTER srasni Oa Ga weet fed ey er ae 55 OIL PUMP ea scene ee ne ate batt wets naar 55 PISTON AND CONNECTING ROD 57 DISASSEMBLY AND ASSEMBLY OIL PUMP 4 2 3 ad eee hes Ce ee 60 VALVE SERVICE WITH THE CYLINDER HEAD REMOVED sas 3 300 Age ia eae de ee 60 CLEANING AND INSPECTION INTAKE MANIFOLUD aaa 63 EXHAUST MANIFOLD 63 CYLINDER HEAD AND CAMSHAFT JOURNALS 5 cheese cca Rene oe 63 OIL PUMP iucia blah geg noe Ra wees See Sx 64 CYLINDER B
42. G ROLL PIN 3 OIL FILTER ADAPTER 2 0L SOHC ENGINE 9 55 OIL FILTER REMOVE AND INSTALL CAUTION When servicing the oil filter Fig 102 avoid deforming the filter Use an appropriate oil fil ter removing tool Position filter wrench strap close the seam at the base of the filter The oil filter seam that joins the can to the base is reinforced by the base plate 1 Turn filter counterclockwise to remove 2 Clean and check the filter mounting surface The surface must be smooth flat and free of debris or old pieces of rubber 3 To install lubricate new filter gasket Screw fil ter on until gasket contacts base Tighten to 21 N m 15 ft Ibs 80bc4d33 Fig 102 Engine Oil Filter 1 OIL FILTER 2 DRAIN PLUG OIL PUMP REMOVAL 1 Disconnect negative cable from battery 2 Remove crankshaft damper timing belt and tensioner Refer to procedures in this section 3 Remove camshaft sprocket and rear timing belt cover Refer to procedures in this section 4 Remove oil pan Refer to procedure in this sec tion 5 Remove crankshaft sprocket using Special Tool 6793 and insert C 4685 C2 Fig 103 6 Remove oil pick up tube 7 Remove oil pump Fig 104 and front crank shaft seal 9 56 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued Fig 103 Crankshaft Sprocket Removal 1 SPECIAL TOOL 6793 2 SPECIAL TOOL C 4685 C2 3 CRANKSHAFT SPROCKET PL INSTALL
43. INSTALLATION 1 Lubricate the camshaft journals with oil and install camshaft without rocker arm assemblies installed 2 Install camshaft target magnet into the end of the camshaft Tighten mounting screw to 3 4 N m 30 in Ibs 3 Install camshaft position sensor and tighten mounting screws to 9 N m 80 in Ibs 4 Measure camshaft end play using the following procedure a Mount dial indicator C 3339 or equivalent to a stationary point on cylinder head Fig 46 b Using a suitable tool move camshaft to rear ward limits of travel c Zero the dial indicator d Move camshaft forward to limits of travel and read dial indicator e End play travel 0 13 0 33 mm 0 005 0 013 in 5 Install front camshaft seal Camshaft must be installed before the camshaft seal is installed Refer to procedure in this section 6 Install cylinder head Refer to procedure in this section 7 Install rear timing belt cover 8 Install camshaft sprocket and tighten to 115 N m 85 ft Ibs 9 Install timing belt tensioner and timing belt Refer to procedures in this section 10 Install rocker arm assemblies in correct order as removed Tighten the rocker arm assemblies in sequence shown in Fig 47 to 28 N m 250 in Ibs 11 Install cylinder head cover and tighten fasten ers to 12 N m 105 in Ibs 80bbdbd5 Fig 47 Rocker Arm Shaft Tightening Sequence 12 Install ignition
44. KE MANIFOLD REMOVAL WARNING RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES NEVER SMOKE WHILE SERVICING THE VEHICLE 1 Disconnect negative cable from battery 2 Remove the inlet air duct from intake manifold to throttle body 3 Perform fuel system pressure release procedure before attempting any repairs Refer to Group 14 Fuel System for procedures WARNING WRAP SHOP TOWELS AROUND FUEL HOSE TO CATCH ANY GASOLINE SPILLAGE 4 Disconnect fuel supply line quick connect at the fuel tube assembly Refer to Group 14 Fuel System for procedures 5 Remove fuel rail assembly attaching screws and remove fuel rail assembly from engine Cover injector holes with suitable covering CAUTION Do not set fuel injectors on their tips damage may occur to the injectors 6 Disconnect brake booster hose Fig 27 and PCV hose Fig 28 from intake manifold 7 Disconnect Manifold Absolute Pressure MAP sensor electrical connector Fig 29 8 Disconnect knock sensor electrical connector Fig 30 9 Disconnect wiring at starter 10 Remove the intake manifold to lower support bracket bolts Fig 31 11 Remove intake manifold screws and washers Discard the fasteners Remove intake manifold INSTALLATION Before installing manifold Clean all mating sur faces Replace all O ring gaskets with new gaskets Fig 33 All intake
45. LOCK AND BORE 65 ADJUSTMENTS ENGINE TORQUE STRUT ADJUSTMENT 66 SPECIFICATIONS 2 0L SOHC ENGINE 2 2 2222 68 TORQUE 1 42242244 ER are eh 71 SPECIAL TOOLS 2 0L SOHC ENGINE 2 22 2222 72 80bc4104 Fig 1 Engine Identification 2 0L 1 ENGINE IDENTIFICATION LOCATION 9 16 2 0L SOHC ENGINE DESCRIPTION AND OPERATION Continued CRANKSHAFT A nodular cast iron crankshaft is used The engine has five main bearings The number three main is flanged to control thrust The mains and connecting rod journals have undercut fillet radiuses that are deep rolled for added strength To optimize bearing loading eight counterweights are used Hydrody namic seals provide end sealing where the crank shaft exits the block Anaerobic gasket material is used for parting line sealing A sintered iron timing belt sprocket is mounted on the crankshaft nose This sprocket transmits crankshaft movement via timing belt to the camshaft sprocket providing timed valve actuation PISTONS The engine DOES NOT have provision for a free wheeling valve train Non free wheeling valve train means in the event of a broken timing belt pistons will contact the valves The engine uses pressed in piston pins to attach forged powdered metal connect ing rods The connecting rods are a cracked cap design and are not repairable Hex head cap screw are used to provide alignment and durability in the assembly Pistons and co
46. Main Bearing Clearance in Standard Service Procedures Refer to Engine Speci fications in this section for crankshaft specifications 9 20 2 0L SOHC ENGINE SERVICE PROCEDURES Continued Fig 8 Connecting Rod Side Clearance CRANKSHAFT END PLAY DIAL INDICATOR METHOD 1 Mount a dial indicator to front of engine locat ing probe on nose of crankshaft Fig 9 LA 9409 189 Fig 9 Checking Crankshaft End Play Dial Indicator 2 Move crankshaft all the way to the rear of its travel 3 Zero the dial indicator 4 Move crankshaft all the way to the front of its travel and read the dial indicator Refer to Engine Specifications in this section for crankshaft specifica tions FEELER GAGE METHOD 1 Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek using care not to dam age any bearing surface Do not loosen main bearing cap PL 2 Use a feeler gauge between number three thrust bearing and machined crankshaft surface to determine end play REMOVAL AND INSTALLATION TORQUE STRUTS UPPER TORQUE STRUT REMOVAL 1 Remove bolts attaching strut to shock tower bracket and engine mount bracket Fig 10 2 Remove the upper torque strut INSTALLATION 1 Position the upper torque strut into mounting locations 2 Install the mounting bolts and perform the torque strut adjustment procedure LOWER TORQUE STRUT REMOVAL
47. N REMOVAL 1 Disconnect negative cable from battery 2 Raise vehicle on hoist 3 Drain engine oil and remove oil filter 4 Remove oil filter adaptor from engine block Fig 81 5 Remove structural collar Refer to procedure in this section 6 Remove lateral bending brace attaching bolts Fig 82 7 Remove lateral bending brace Fig 82 8 Remove transaxle dust cover Fig 82 9 Remove oil pan bolts 10 Remove oil pan INSTALLATION 1 Clean oil pan and all sealing surfaces 9 48 2 0L SOHC ENGINE _ _qqwuc mqm HL REMOVAL AND INSTALLATION Continued NY r AE N z Si eK Mv 9409 59 Q 9509 42 Fig 81 Oil Filter Adaptor Fig 83 Oil Pan Sealing 1 O RING 1 PLACE A 1 8 INCH BEAD OF SEALER AT THE PARTING 2 LOCATING ROLL PIN LINE OF THE OIL PUMP TO ENGINE BLOCK 3 OIL FILTER ADAPTER 7 Install structural collar Refer to procedure in this section 8 Install oil filter adaptor and tighten assembly to 80 N m 60 ft Ibs Fig 81 9 Install oil filter 10 Lower vehicle and fill engine crankcase with proper oil to correct level CRANKSHAFT OIL SEAL FRONT REMOVAL 1 Remove accessory drive belts Refer to Group 7 Cooling System for procedures 2 Remove crankshaft damper Refer to procedure in this section 3 Remove front timing belt cover and timing belt Refer to procedures in this sect
48. N Begin with a thorough visual inspection of the engine particularly at the area of the suspected leak If an oil leak source is not readily identifiable the following steps should be followed 1 Do not clean or degrease the engine at this time because some solvents may cause rubber to swell temporarily stopping the leak 2 Add an oil soluble dye use as recommended by manufacturer Start the engine and let idle for approximately 15 minutes Check the oil dipstick to 9 10 ENGINE DIAGNOSIS AND TESTING Continued make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light 3 Using a black light inspect the entire engine for fluorescent dye particularly at the suspected area of oil leak If the oil leak is found and identified repair per service manual instructions 4 If dye is not observed drive the vehicle at var ious speeds for approximately 24 km 15 miles and repeat inspection 5 If the oil leak source is not positively identified at this time proceed with the air leak detection test method as follows e Disconnect the fresh air hose makeup air at the cylinder head cover and plug or cap the nipple on the cover e Remove the PCV valve hose from the cylinder head cover Cap or plug the PCV valve nipple on the cover e Attach an air hose with pressure gauge and reg ulator to the dipstick tube CAUTION Do not subject the engine assembly to more than 20 6 kpa 3 PSI
49. NE 80bceala 80bbc30a PL ADJ USTMENTS Continued 2 ENGINE MOUNT BRACKET 3 TORQUE STRUT BRACKET 4 UPPER TORQUE STRUT 1 BOLTS A Sg E P Z Ser E L 3 SI g A E FIIR E S LNI oO 2 D E n D eW ooo ee eg E mz amp wu m CO HI N Sa el Ce uO sr H Soc u D Dok S D Oz d d OOL GO 20 Za III Nin ono 3 S e e K 8 8 D Fig 136 Floor Jack Positioning 1 WOOD BLOCK 2 FLOOR JACK 9 68 2 0L SOHC ENGINE e BE SPECIFICATIONS DESCRIPTION SPECIFICATION 2 0L SOHC ENGINE Piston Ring Groove 3 847 4 131 mm Dep Noa 0 151 0 163 in DESCRIPTION SPECIFICATION Pistons Low Emission Vehicle LEV ULEV General Specification 87 456 87 474 mm In Line OHV SOHC Clearance 10 42 mm 0 018 0 50 mm Number or C pindar 0 42 in from bottom of 3 4432 3 4439 in Displacement 2 0 Liters skirt 0 0008 0 0020 in 122 cu in Weight 320 329 grams Bore 87 5 mm 11 29 11 60 oz 3 445 in Land Clearance 0 758 0 790 mm Diametrical 0 0299 0 0312 in 83 0 mm 3 268 in Piston Length 55 8 mm Compression Fal 2197 in Firing Order 1 3 4 2 Piston Ring Groove 3 989 4 188 mm Compression Pressure 1172 1551 kPa Depth No 1 0 157 0 165 in 170 225 psi Piston Ring Groove 4 462 4 661 mm Max Variation Between Depth No 2 0 176 0 184 in Piston Ring Groove 3 847 4 131 mm Cylinder Block Depth No 3 0 151 0 163 in S
50. PL ENGINE TABLE OF CONTENTS page STANDARD SERVICE PROCEDURES 1 ENGINE DIAGNOSIS u uuu0suu0nu0 KE KN 8 STANDARD SERVICE PROCEDURES TABLE OF CONTENTS page GENERAL INFORMATION FORM IN PLACE GASKETS A SEALERS 1 ENGINE GASKET SURFACE PREPARATION 2 CRANKSHAFT DAMPER BOLT ACCESS PLUG 2 ENGINE CORE PLUGS 2 ENGINE PERFORMANCE 3 GENERAL INFORMATION FORM IN PLACE GASKETS amp SEALERS There are numerous places where form in place gaskets are used on the engine Care must be taken when applying form in place gaskets to assure obtaining the desired results Do not use form in place gasket material unless specified Bead size continuity and location are of great importance Too thin a bead can result in leakage while too much can result in spill over which can break off and obstruct fluid feed lines A continuous bead of the proper width is essential to obtain a leak free gasket There are numerous types of form in place gasket materials that are used in the engine area Mopar Engine RTV GEN II Mopar ATF RTV and Mopar Gasket Maker gasket materials each have different properties and can not be used in place of the other MOPAR ENGINE RTV GEN Il Mopar Engine RTV GEN II is used to seal com ponents exposed to engine oil This material is a spe cially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed
51. SU DS QUES 7 IT K N 80bc4cb3 Fig 52 Valve Spring Removing and Installing 1 VALVE SPRING COMPRESSOR SPECIAL TOOL MD 998772A 2 ADAPTER 6779 3 AIR HOSE 5 Remove valve spring 6 Remove valve stem seal by using a valve stem seal tool Fig 53 PL Fig 53 Valve Stem Oil Seal Tool 1 VALVE SEAL TOOL 2 VALVE STEM INSTALLATION 1 Install valve seal valve spring seat assembly Refer to Valve Installation procedure in this section 2 Using Special Tool MD 998772A compress valve springs only enough to install locks Correct align ment of tool is necessary to avoid nicking valve stems air pressure required piston at TDC Of gt Z amp 9509 48 Fig 54 Valve Spring Assembly 1 VALVE RETAINING LOCKS 2 VALVE SPRING 3 VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY 4 VALVE SPRING RETAINER 3 Install rocker arm shaft assemblies Refer to procedure in this section 4 Install cylinder head cover Refer to procedure in this section PL REMOVAL AND INSTALLATION Continued CYLINDER HEAD REMOVAL 1 Perform fuel system pressure release procedure before attempting any repairs Refer to Group 14 Fuel System 2 Disconnect negative battery cable 3 Remove power steering air conditioning drive belt Refer to Group 7 Cooling System Accessory Drive for procedure 4 Raise vehicle 5 Drain cooling system Refer to Group 7 Cooling
52. VERS FRONT TIMING BELT COVER REMOVAL 1 Remove accessory drive belts Refer to Group 7 Cooling System for procedure 2 Remove crankshaft damper Refer to procedure in this section 3 Remove lower and upper torque struts Refer to procedure in this section 4 Position a jack under engine Raise jack enough to support engine weight 5 Remove right engine mount to engine mount bracket bolt 6 Remove power steering pump assembly and set aside 7 Remove right engine mount bracket 8 Remove front timing belt cover Fig 64 2 0L SOHC ENGINE 9 41 80be4ch1 Fig 64 Front Timing Belt Cover 1 ACCESS PLUG 2 BOLTS INSTALLATION 1 Install front timing belt cover and tighten bolts to 12 Nm 105 in Ibs 2 Install front engine mount bracket 3 Install right side engine mount to engine mount bracket bolt 4 Remove jack from under engine 5 Install power steering pump assembly 6 Install upper and lower engine torque struts Refer to procedure in this section 7 Install crankshaft damper Refer to procedure in this section 8 Install accessory drive belts Refer to Group 7 Cooling System Accessory Drive section for proce dure REAR TIMING BELT COVER REMOVAL 1 Remove front timing belt cover following proce dure in this section 2 Remove timing belt and timing belt tensioner Refer to procedures in this section 3 Hold camshaft sprocket with Special Tools C 4687
53. WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL PROPERLY CONTACT YOUR DEALER OR GOVERN MENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA ENGINE OIL SPECIFICATION CAUTION Do not use non detergent or straight mineral oil when adding or changing crankcase lubricant Engine failure can result API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certi fied MOPAR provides engine oils that conforms to this service grade SAE VISCOSITY An SAE viscosity grade is used to specify the vis cosity of engine oil Use only engine oils with multi ple viscosities such as 5W 30 or 10W 30 These are specified with a dual SAE viscosity grade which indi cates the cold to hot temperature viscosity range SAE 5W 30 engine oil is preferred Select an engine oil that is best suited to your particular temperature range and variation Fig 9 ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines The designation of ENERGY CON SERVING is located on the label of the engine oil container CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans Fig 10 ENGINE OIL CHANGE Change engine oil at mileage and time intervals
54. Worn valve guides 8 Excessive runout of valve seats on valve faces 9 Missing adjuster pivot 1 Check and correct engine oil level 2 Change oil to correct viscosity 3 Check and correct engine oil level 4 Replace rocker arm hydraulic lash adjuster assembly 5 Inspect oil supply to rocker arms 6 Install new rocker arm hydraulic lash adjuster assembly 7 Ream guides and install new valves with oversize stems 8 Grind valve seats and valves 9 Replace rocker arm hydraulic lash adjuster assembly CONNECTING ROD NOISE 1 Insufficient oil supply 2 Low oil pressure 3 Thin or diluted oil 4 Excessive bearing clearance 5 Connecting rod journal out of round 6 Misaligned connecting rods 1 Check engine oil level 2 Check engine oil level Inspect oil pump relief valve and spring 3 Change oil to correct viscosity 4 Measure bearings for correct clearance Repair as necessary 5 Replace crankshaft or grind surface 6 Replace bent connecting rods PL DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES ENGINE 9 13 CORRECTION MAIN BEARING NOISE 1 Insufficient oil supply 2 Low oil pressure 3 Thin or diluted oil 4 Excessive bearing clearance 5 Excessive end play 6 Crankshaft journal out of round or worn 7 Loose flywheel or torque converter 1 Check engine oil level 2 Check engine oil level Inspect oil pump reli
55. accessory drive belts Refer to Group 7 Cooling System for procedures 17 Install right inner splash shield 18 Lower vehicle and perform camshaft and crankshaft timing relearn procedure as follows e Connect the DRB scan tool to the data link diagnostic connector This connector is located in the passenger compartment at the lower edge of instrument panel near the steering column e Turn the ignition switch on and access the mis cellaneous screen e Select relearn cam crank option and follow directions on DRB screen PL Fig 77 Crankshaft Damper Installation 1 M12 1 75 x 150 MM BOLT WASHER AND THRUST BEARING FROM SPECIAL TOOL 6792 TIMING BELT TENSIONER REMOVAL 1 Remove timing belt Refer to procedure in this section 2 Remove tensioner assembly attaching bolts Fig 78 3 Remove tensioner assembly CAUTION The timing belt tensioner is serviced as an assembly To prevent premature timing belt fail ure DO NOT separate the tensioner pulley from mounting bracket INSTALLATION 1 Install timing belt tensioner assembly Tighten attaching bolts to 31 N m 275 in Ibs 2 Install timing belt Refer to procedure in this section CAMSHAFT OIL SEAL REMOVAL CAUTION Do Not Rotate the camshaft or crank shaft when timing belt is removed damage to the engine may occur 1 Remove crankshaft damper front timing belt cover timing belt and tensioner assembly Refer to pro
56. ace as necessary Refer to Group 14 Fuel System 4 Correct valve timing 5 Replace cylinder head gasket 6 Test compression of each cylinder 7 Replace valves 8 Install new parts as necessary 9 Test and replace as necessary Refer to Group 8D Ignition System 9 12 ENGINE DIAGNOSIS AND TESTING CONDITION Continued POSSIBLE CAUSE PL CORRECTION ENGINE MISSES ON ACCELERATION 1 Dirty or incorrectly gapped spark plugs Contamination in Fuel System Burned warped or pitted valves Faulty coil s 1 Clean spark plugs and set gap Refer to Group 8D Ignition System 2 Clean fuel system and replace fuel filter 3 Replace valves 4 Test and replace as necessary Refer to Group 8D Ignition System ENGINE MISSES AT HIGH SPEED Dirty or incorrect spark plug gap Faulty coil s Dirty fuel injector s Contamination in fuel system ENGINE DIAGNOSIS MECHANICAL CONDITION POSSIBLE CAUSES 1 Clean spark plugs and set gap Refer to Group 8D Ignition System 2 Test and replace as necessary Refer to Group 8D Ignition System Test and replace as necessary Refer to Group 14 Fuel System 4 Clean system and replace fuel filter CORRECTION NOISY VALVES 1 High or low oil level in crankcase 2 Thin or diluted oil 3 Low oil pressure 4 Dirt in tappets lash adjusters 5 Worn rocker arms 6 Worn tappets lash adjusters 7
57. and modified Adaptor C 4687 1 Fig 66 while removing attaching bolt 4 Remove camshaft sprocket 5 Remove rear timing cover attaching bolts Fig 65 6 Remove rear timing cover Fig 65 9 42 2 0L SOHC ENGINE PL REMOVAL AND INSTALLATION Continued ISS CC N 80bc4d3h Fig 65 Rear Timing Belt Cover 1 BOLTS INSTALLATION 1 Install rear timing cover and tighten bolts to 12 N m 105 in Ibs Fig 65 2 Install camshaft sprocket While holding sprockets with Special Tools C 4687 and modified 9509 65 Fig 66 Modification to Special Tool C 4687 1 1 GRIND LOCATION 2 12 7 MM 1 2 IN 3 50 8 MM 2 IN Adaptor C 4687 1 tighten attaching bolt to 101 N m 75 ft Ibs 3 Install timing belt tensioner assembly and tim ing belt Refer to procedure in this section 4 Install front timing belt cover following proce dure in this section PL REMOVAL AND INSTALLATION Continued TIMING BELT 9 43 2 0L SOHC ENGINE 80add3fc Fig 67 Timing Belt System 7 TIMING BELT 8 BOLT 9 CRANKSHAFT DAMPER 10 FRONT TIMING BELT COVER 11 ACCESS PLUG 12 CAMSHAFT BOLT AND WASHER 1 CAMSHAFT SPROCKET 2 REAR TIMING BELT COVER 3 TIMING BELT TENSIONER ASSEMBLY 4 WATER PUMP 5 OIL PUMP BODY 6 CRANKSHAFT SPROCKET CHECKING BELT TIMING COVER INSTALLED e Remove number one spark plug e Using a dial indicator
58. at the tapped holes maintain the original centerline Heli Coil tools and inserts are readily available from automotive parts jobbers HYDROSTATIC LOCKED ENGINE When an engine is suspected to be hydrostatically locked regardless of what caused the problem the following steps should be used CAUTION DO NOT use starter motor to rotate the engine severe damage may occur 1 Inspect air cleaner induction system and intake manifold to insure system is dry and clear of foreign material 2 Remove negative battery cable 3 Place a shop towel around the spark plugs when removing them from the engine This will catch 9 6 ENGINE GENERAL INFORMATION Continued any fluid that may possibly be in the cylinder under pressure 4 With all spark plugs removed rotate engine crankshaft using a breaker bar and socket 5 Identify the fluid in the cylinder s i e cool ant fuel oil or other 6 Make sure all fluid has been removed from the cylinders Inspect engine for damage i e connecting rods pistons valves etc 7 Repair engine or components as necessary to prevent this problem from re occurring CAUTION Squirt approximately one teaspoon of oil into the cylinders rotate engine to lubricate the cyl inder walls to prevent damage on restart 8 Install new spark plugs 9 Drain engine oil and remove oil filter 10 Fill engine with specified amount of approved oil and install new oil filter 11 Conn
59. cedures in this section 2 Hold camshaft sprocket with Special Tools C 4687 and modified C 4687 1 as shown in Fig 79 while removing attaching bolt 3 Remove sprocket from camshaft 4 Remove rear timing belt cover PL REMOVAL AND INSTALLATION Continued 80add406 Fig 78 Timing Belt Tensioner Assembly Removal Installation 1 TIMING BELT TENSIONER ASSEMBLY 2 TENSIONER ASSEMBLY ATTACHING BOLTS 9509 65 Fig 79 Modification to Special Tool 1 GRIND LOCATION 2 12 7 MM 1 2 IN 3 50 8 MM 2 IN 5 Remove camshaft seal by carefully using a suit able pry tool Be careful not to nick or damage the 2 0L SOHC ENGINE 9 47 camshaft seal surface or cylinder head seal retaining bore CAUTION Do not nick shaft seal surface or seal bore 6 Shaft seal lip surface must be free of varnish dirt or nicks Polish with 400 grit paper if necessary INSTALLATION 1 Install camshaft seal flush with cylinder head using Special Tool MD998306 Fig 80 Fig 80 Camshaft Oil Seal Installation 1 SPECIAL TOOL MD 998306 9509 9 2 Install rear timing belt cover 3 Install camshaft sprocket retaining bolt Hold camshaft sprocket with Special Tools C 4687 and modified C 4687 1 Fig 79 and tighten bolt to 115 N m 85 ft Ibs 4 Install timing belt tensioner timing belt front cover and crankshaft damper Refer to procedures in this section OIL PA
60. clean engine oil slide the ring compressor over the piston 2 0L SOHC ENGINE os Do 9 59 amp FRONT OF ENGINE SS a 9509 46 Fig 114 Piston Ring End Gap Position 1 GAP OF LOWER SIDE RAIL 2 NO 1 RING GAP 3 GAP OF UPPER SIDE RAIL 4 NO 2 RING GAP AND SPACER EXPANDER GAP Fig 115 Be sure position of rings does not change during this operation Fig 115 Installing Piston 4 The weight stamp designation L or H will bein the front half of the piston should face toward the front of the engine Fig 108 5 Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore Lubri cate connecting rod journal with clean engine oil 6 Position upper bearing half and install Special Tool 8189 connecting rod guides onto connecting rod Fig 110 7 Insert rod and piston assembly into cylinder bore and carefully guide rod over the crankshaft jour nal 8 Tap the piston down in cylinder bore using a hammer handle At the same time guide connecting rod into position on connecting rod journal 9 Remove Special Tool 8189 connecting rod guides 9 60 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued 10 Install connecting rod lower bearing half and cap Install New bolts and tighten to 27 N m 20 ft Ibs plus 1 4 turn 11 Install cylinder head and oil pan Refer to pro cedures in this section DISASSEMBLY AND ASSEMBLY OIL PUMP 1 To remove the relief
61. coat valve seat LIGHTLY with Prussian blue 9 62 2 0L SOHC ENGINE DISASSEMBLY AND ASSEMBLY Continued then set valve in place Rotate the valve with light pressure If the blue is transferred to the center of valve face contact is satisfactory If the blue is trans ferred to top edge of the valve face lower valve seat with a 15 degrees stone If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone 6 Valve seats which are worn or burned can be reworked provided that correct angle and seat width are maintained The intake valve seat must be ser viced when the valve seat width is 2 0 mm 0 079 in or greater The exhaust valve seat must be serviced when the valve seat width is 2 5 mm 0 098 in or greater Otherwise the cylinder head must be replaced 7 When seat is properly positioned the width of intake and exhaust seats should be 0 75 1 25 mm 0 030 0 049 in Fig 122 Kazen E oo gt A SEAT WIDTH INTAKE AND EXHAUST 0 9 TO 1 3 mm 035 TO 051 IN B FACE ANGLE INTAKE amp EXHAUST 44 2 45 C SEAT ANGLE INTAKE A EXHAUST 45 45 2 D SEAT CONTACT AREA E SEAT DIAMETER 9509 207 Fig 122 Valve Seat Refacing 8 Check valve tip to spring seat dimensions A after grinding the valve seats or faces Grind valve tip until within specifications Measure from valve tip to spring seat when installed in the head mea surement A Fig 123
62. d is a molded plastic composi tion attached to the cylinder head with five fasten ers This long branch design enhances low and mid range torque EXHAUST MANIFOLD The exhaust manifold is made of nodular cast iron for strength and high temperatures Exhaust gasses exit the manifold into an articulated joint connection and exhaust pipe COMPONENT REPLACEMENT If any of the following parts have been changed or replaced e Camshaft e Camshaft Position Sensor Camshaft Position Sensor Target Magnet Cylinder Block Cylinder Head Water Pump e Powertrain Control Module PCM e Timing Belt and Timing Belt Tensioner The camshaft and crankshaft timing relearn proce dure must be performed Refer to the component Removal and Installation procedure in this section PL DESCRIPTION AND OPERATION Continued ENGINE LUBRICATION SYSTEM 2 0L SOHC ENGINE 9 17 80a53b24 Engine Lubrication Components 1 O RING 2 OIL FILTER ADAPTER 3 OIL PAN GASKET 4 OIL PAN 5 OIL PICK UP TUBE 6 DRAIN PLUG ENGINE LUBRICATION Refer to Group 0 Lubrication and Maintenance for recommended oil capacity to be used in various engine application System is full flow filtration pressure feed type The oil pump is mounted in the front engine cover and driven by the crankshaft Pressurized oil is then routed through the main oil gallery running the length of the cylinder block sup plying main and rod bearings with
63. e ees oe Ce 3 4446 3 4452 in Clearance in Piston 0 008 0 015 mm Out of Round Max 0 051 mm 0 0003 0 0006 in 0 002 in Clearance in Connecting Interference Taper Max 0 051 mm Rod 0 002 in Diameter 21 000 21 003 mm Pistons Federal Emission 0 8268 0 8269 in Piston Diameter 87 463 87 481 mm End Play None 3 4434 3 4441 in Length 74 75 75 25 mm 2 Y z Oo CH a e S 3 D 2 07 Clearance 17 5 mm 0 012 0 044 mm 2 943 2 963 in 11 16 in from bottom of z GO 0 0004 0 0017 in Piston Rings Ring Gap Top 0 23 0 52 mm Weight 325 335 grams Compression Ring Freres 11 47 11 82 oz i f i Diametrical 0 029 0 031 in m M ing Gap 2n 49 0 78 mm SECH u Compression Ring 0 019 0 031 in 2 520 in i i Depth No 1 0 157 0 165 in _ 0 039 in Piston Ring Groove 4 462 4 661 mm a N control ee a PL SPECIFICATIONS Continued DESCRIPTION SPECIFICATION Wear Limit 1 0 mm 0 039 in 0 025 0 065 mm 0 0010 0 00286 in Wear Limit 0 10 mm 0 004 in Ring Side Clearance Oil 0 004 0 178 mm Ring Pack 0 0002 0 0070 in Ring Width 1 17 1 19 mm Compression Rings 0 046 0 047 in Ring Width Oil Ring 2 854 3 008 mm Pack 0 1124 0 1184 in Connecting Rod 0 026 0 059 mm 0 001 0 0023 in Wear Limit 0 075 mm 0 003 in Bore Diameter Piston 20 96 20 98 mm Pin 0 8252 0 8260 in Bore Diameter 50 991 51 005 mm Crankshaft End 2 0075 2 0081 in 0 13
64. e until it contacts the stop While holding tensioner pulley against stop insert a 1 8 or 3 mm diameter pin or Allen wrench through the hole located to the left of the hex opening Fig 72 While pushing pin into hole allow the tensioner pulley to rotate back Almost immediately the pin should engage the lock ing hole to prevent further movement of the pulley 12 Remove timing belt CAUTION Do not rotate the camshafts once the timing belt has been removed or damage to valve components may occur PL 80bc4d2t Fig 70 Right Engine Mount Bracket 1 BOLTS 2 ENGINE MOUNT BRACKET ASSEMBLY 80be4ch1 Fig 71 Timing Belt Cover 1 ACCESS PLUG 2 BOLTS PL REMOVAL AND INSTALLATION Continued O O O Q gt 5 Q Q Q yv O Q OPEL mc RO Y 80add3fe Fig 72 Timing Belt Removal 1 CAMSHAFT TIMING MARKS 2 BELT TENSIONER 3 CRANKSHAFT AT TDC 4 1 8 OR 3mm ALLEN WRENCH 5 8 mm ALLEN WRENCH CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND BELT INSTALLATION 1 Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing then back off to 3 notches before TDC Fig 73 80900897 Fig 73 Crankshaft Sprocket Timing 1 TDC MARK 2 0L SOHC ENGINE 9 45 9509 67 Fig 74 Camshaft Timing Mark 1 CAM SPROCKET TIMING MARK 2 ARROW ON RE
65. ease procedure before attempting any repairs Refer to Group 14 Fuel System 2 Remove the cylinder head cover Refer to proce dure in this section 3 Mark rocker arm shaft assemblies so that they are installed in their original positions 4 Remove rocker arm shaft bolts Refer to proce dure in this section 5 Remove timing belt timing belt tensioner and camshaft sprocket Refer to procedures in this sec tion 6 Remove rear timing belt cover 7 Remove cylinder head Refer to procedure in this section 8 Remove camshaft sensor and camshaft target magnet 9 Remove camshaft from the rear of cylinder head 9 34 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued INSPECT CYLINDER HEAD FOR THE FOLLOWING NOTE e Check oil feed holes for blockage e Inspect cylinder head camshaft bearings for wear Refer to Cylinder Head Inspection and Clean ing e Check camshaft bearing journals for scratches and worn areas If light scratches are present they may be removed with 400 grit sand paper If deep scratches are present replace the camshaft and check the cylinder head for damage Replace the cylinder head if worn or damaged Check the lobes for pitting and wear If the lobes show signs of wear check the corresponding rocker arm roller for wear or damage Replace rocker arm hydraulic lash adjuster if worn or damaged If lobes show signs of pitting on the nose flank or base circle replace the camshaft
66. easurement must be made with the ring positioned below normal ring travel in the cylinder bore Check gap with feeler gauge Fig 5 Refer to Engine Specifications in this section for piston ring specifications 9309 157 Fig 5 Piston Ring Gap 1 FEELER GAUGE 2 Check piston ring to groove side clearance Fig 6 Refer to Engine Specifications in this section for piston ring specifications FITTING CONNECTING RODS 1 Follow the procedure specified in the Standard Service Procedures Section for Measuring Main Bear ing Clearance and Connecting Rod Bearing Clear 2 0L SOHC ENGINE 9 19 Fig 6 Piston Ring Side Clearance 1 FEELER GAUGE ance Fig 7 Refer to Engine Specifications in this section for connecting rod specifications CAUTION Do not rotate crankshaft or the Plasti gage may be smeared 9509 37 Fig 7 Connecting Rod Bearing Clearance NOTE The rod bearing bolts should not be reused 2 Before installing the NEW bolts the threads should be oiled with clean engine oil 3 Install each bolt finger tight than alternately torque each bolt to assemble the cap properly 4 Tighten the bolts to 27 N m PLUS 1 4 turn 20 ft Ibs PLUS 1 4 turn Do not use a torque wrench for last step 5 Using a feeler gauge check connecting rod side clearance Fig 8 Refer to Engine Specifications in this section for connecting rod specifications FITTING CRANKSHAFT BEARINGS Refer to Measuring
67. ect negative battery cable 12 Start engine and check for any leaks CHECKING ENGINE OIL LEVEL The best time to check engine oil level is after it has sat overnight or if the engine has been running PL allow the engine to be shut off for at least 5 minutes before checking oil level Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading Remove dipstick Fig 7 and observe oil level Add oil only when the level is at or below the ADD mark Fig 8 80161b9a Fig 8 Oil Level 1 ENGINE OIL LEVEL DIPSTICK ei 4 d ff aye A gal a by NN DID eS ell yoo Tr D e eh i y On nt EE CT eS A LA D O j R crass Gu Siok ji o gt KE gt i ONE ee _ fs SS IN ren hese 80pb 300 Fig 7 Dipstick and Engine Oil Fill Locations 1 ENGINE OIL FILL 2 ENGINE COOLANT RECOVERY CONTAINER 3 ENGINE OIL DIPSTICK 4 COOLING SYSTEM PRESSURE CAP PL GENERAL INFORMATION Continued ENGINE OIL SERVICE WARNING NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL CONTAMINANTS IN USED ENGINE OIL CAUSED BY INTERNAL COMBUSTION CAN BE HAZARDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN
68. ed 17 Install rear timing belt cover and camshaft sprocket 18 Install crankshaft sprocket timing belt ten sioner timing belt and cover 19 Install front engine mount bracket 20 Remove engine from repair stand and position on Special Tools 6135 and 6710 Engine Dolly and Cradle Install safety straps around the engine to cradle and tighten and lock them into position 21 Install crankshaft rear oil seal Refer to proce dure in this section 22 Install drive plate flywheel Apply Mopar Lock amp Seal Adhesive to bolt threads and tighten to 95 N m 70 ft Ibs 23 Install transaxle to engine 24 Install structural collar Refer to procedure in this section 25 Install engine assembly Refer to procedure in this section 26 Perform camshaft and crankshaft timing relearn procedure as follows e Connect the DRB scan tool to the data link diagnostic connector This connector is located in the passenger compartment at the lower edge of instrument panel near the steering column e Turn the ignition switch on and access the mis cellaneous screen e Select relearn cam crank option and follow directions on DRB screen OIL FILTER ADAPTER REMOVE AND INSTALL Ensure O ring is in the groove on adapter Align roll pin into engine block and tighten assembly to 80 N m 60 ft Ibs Fig 101 A 9409 59 Fig 101 Engine Oil Filter Adapter to Engine Block 1 O RING 2 LOCATIN
69. ef valve and spring 3 Change oil to correct viscosity 4 Measure bearings for correct clearance Repair as necessary 5 Check thrust bearing for wear on flanges 6 Replace crankshaft or grind journals 7 Tighten to correct torque OIL PRESSURE DROP 1 Low oil level 2 Faulty oil pressure sending unit 3 Low oil pressure Clogged oil filter Worn parts in oil pump Thin or diluted oil Oil pump relief valve stuck Oil pump suction tube loose 9 Oil pump cover warped or cracked 10 Excessive bearing clearance 1 Check engine oil level 2 Install new sending unit 3 Check sending unit and main bearing oil clearance 4 Install new oil filter 5 Replace worn parts or pump 6 Change oil to correct viscosity 7 Remove valve and inspect clean or replace 8 Remove oil pan and install new tube or clean if necessary 9 Install new oil pump 10 Measure bearings for correct clearance OIL LEAKS 1 Misaligned or deteriorated gaskets 2 Loose fastener broken or porous metal part 3 Misaligned or deteriorated cup or threaded plug 1 Replace gasket s 2 Tighten repair or replace the part 3 Replace as necessary 9 14 ENGINE DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES PL CORRECTION OIL CONSUMPTION OR SPARK PLUGS FOULED 1 PCV system malfunction 2 Worn scuffed or broken rings 3 Carbon in oil
70. ensioner timing belt and front timing belt cover 11 Install crankshaft damper 12 Fill engine crankcase with proper oil to cor rect level 13 Connect negative cable to battery PISTON AND CONNECTING ROD REMOVAL 1 Remove cylinder head and oil pan Refer to pro cedures in this section 2 Remove top ridge of cylinder bores with a reli able ridge reamer before removing pistons from cyl inder block Be sure to keep tops of pistons covered during this operation Mark piston with matching cylinder number Fig 108 9509 248 Fig 108 Piston Markings 1 WEIGHT DESIGNATION AND DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA CAUTION DO NOT use a number stamp or a punch to mark connecting rods Damage to connecting rod could occur 3 Using a permanent ink marker or scribe tool mark the cylinder number on the side of the rod and cap Fig 109 for identification 9 58 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued Fig 109 Identify Connecting Rod to Cylinder 4 Pistons will have a stamping in the approxi mate location shown in Fig 108 These stamps will be either a directional arrow or a weight identifica tion for the assembly L is for light and H is for heavy These assemblies should all be the same weight class Service piston assemblies are marked with a S and can be used with either L or H produc tion assemblies The weight designation stamps should face toward the timing belt
71. f valve guides with a reliable guide cleaner 2 Using a small hole gauge and a micrometer measure valve guides in 3 places top middle and bot tom Fig 118 Replace guides if they are not within specification For specifications refer to Engine Spec ifications in this section 3 Check valve guide height Fig 119 TESTING VALVE SPRINGS 1 Whenever valves have been removed for inspec tion reconditioning or replacement valve springs should be tested Special Tool C 647 As an example the compression length of the spring to be tested is 33 34 mm 1 5 16 in Turn tool table until surface is in line with the 33 34 mm 1 5 16 in mark on the threaded stud and the zero mark on the front Place spring over stud on the table and lift compressing lever to set tone device Fig 120 Pull on torque PL DISASSEMBLY AND ASSEMBLY Continued 9109 98 Fig 118 Checking Wear on Valve Guide Typical 1 TOP 2 MIDDLE 3 BOTTOM 4 CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT LOCATIONS 9509 19 Fig 119 Valve Guide Height 1 VALVE GUIDE 2 13 25 13 75 MM 0 521 0 541 in 3 SPRING SEAT wrench until ping is heard Take reading on torque wrench at this instant Multiply this reading by two This will give the spring load at test length Frac tional measurements are indicated on the table for finer adjustments Discard the springs that do not meet specifications The following specifications apply
72. he area between the bedplate and cyl inder block without disturbing the bearing clearance or alignment of these components The material cures slowly in the absence of air when torqued between two metallic surfaces and will rapidly cure when heat is applied 9 2 ENGINE GENERAL INFORMATION Continued MOPAR GASKET SEALANT Mopar Gasket Sealant is a slow drying perma nently soft sealer This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant Can be used on threaded and machined parts under all temperatures This mate rial is used on engines with multi layer steel MLS cylinder head gaskets This material also will pre vent corrosion Mopar Gasket Sealant is available in a 13 oz aerosol can or 4 0z 16 oz can w applicator FORM IN PLACE GASKET AND SEALER APPLICATION Assembling parts using a form in place gasket requires care but it s easier then using precut gas kets Mopar Gasket Maker material should be applied sparingly 1 mm 0 040 in diameter or less of sealant to one gasket surface Be certain the material sur rounds each mounting hole Excess material can eas ily be wiped off Components should be torqued in place within 15 minutes The use of a locating dowel is recommended during assembly to prevent smear ing material off the location Mopar Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm 0 120 in
73. hield for access to mani fold bolts 12 Remove exhaust manifold bolts 13 ULEV equipped remove cylinder head cover Refer to procedure in this section Cover cylinder head opening with a suitable covering 14 Remove exhaust manifold from top of vehicle between cylinder head and cowl PL Fig 34 Wire Harness Heat Shield Boli Federal amp LEV Shown ULEV Similar 1 BOLT 2 BRACKET 3 HEAT SHIELD GN 2 TAN E un N 80bce99h Fig 35 Exhaust Manifold Support Bracket Federal amp LEV 1 BRACKET 2 BOLT M10 3 BOLT M12 4 NUT INSTALLATION 1 Position exhaust manifold and gasket in place 2 Install exhaust manifold bolts and tighten in sequence shown in Fig 38 to 23 N m 200 in Ibs 3 ULEV equipped position upper heat shield on exhaust manifold Install bolts and tighten to 23 N m 200 in Ibs 4 Position lower and upper heat shield on exhaust manifold Install heat shield bolts and tighten to 11 N m 95 in Ibs Fig 37 5 Connect oxygen sensor electrical connector and harness clip 6 ULEV equipped install cylinder head cover Refer to procedures in this section PL REMOVAL AND INSTALLATION Continued LESS OOD BES deg 80bce996 Fig 36 Exhaust Manifold Support Bracket ULEV 1 MANIFOLD SUPPORT BRACKET 2 OIL FILTER 3 BOLTS EE ARD gt i po er 80bc4d2 Fig 37 Exhaust Ma
74. ight after refacing the valve and seat measurment B Fig 123 Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer If height is greater than 40 18 mm 1 58 in install PL DISASSEMBLY AND ASSEMBLY Continued a 0 762 mm 0 030 in spacer under the valve spring seat to bring spring height back within specification 5 Install rocker arm shafts as previously described in this section 6 Checking dry lash Dry lash is the amount of clearance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed Specified dry lash is 1 17 mm 0 046 in for intake and 1 28 mm 0 050 in for exhaust After performing dry lash check refill adjuster with oil and allow 10 minutes for adjuster s to bleed down before rotating cam CLEANING AND INSPECTION INTAKE MANIFOLD CLEAN AND INSPECT Check for e Inspect manifold for cracks or distortions e Check for torn or missing O rings at the mating surface of the manifold Fig 125 80bc4c7e Fig 125 Intake Manifold O Rings 1 INTAKE MANIFOLD O RING GASKETS EXHAUST MANIFOLD CLEAN AND INSPECT 1 Discard gasket and clean all gasket surfaces of manifolds and cylinder head 2 Test manifold gasket surfaces for flatness with straight edge Surface must be flat within 0 15 mm per 300 mm 006 in per foot of manifold length
75. in diameter All mounting holes must be circled For corner sealing a 3 17 or 6 35 mm 1 8 or 1 4 in drop is placed in the center of the gasket contact area Uncured sealant may be removed with a shop towel Components should be torqued in place while the sealant is still wet to the touch within 10 minutes The usage of a locating dowel is recommended during assembly to prevent smearing material off the location Mopar Gasket Sealant in an aerosol can should be applied using a thin even coat sprayed completely over both surfaces to be joined and both sides of a gasket Then proceed with assembly Material in a can w applicator can be brushed on evenly over the sealing surfaces Material in an aerosol can should be used on engines with multi layer steel gaskets ENGINE GASKET SURFACE PREPARATION To ensure engine gasket sealing proper surface preparation must be performed especially with the use of aluminum engine components and multi layer steel cylinder head gaskets Never use the following to clean gasket surfaces e Metal scraper e Abrasive pad or paper to clean cylinder block and head e High speed power tool with an abrasive pad or a wire brush Fig 1 PL NOTE Multi Layer Steel MLS head gaskets require a scratch free sealing surface Only use the following for cleaning gasket surfaces e Solvent or a commercially available gasket remover e Plastic or wood scraper Fig 1 e Drill motor with 3M Roloc Bristle
76. ing a permanent ink marker or equivalent mark the position of engine mount to the body frame rail while maintaining mounting hole concentricity 3 Ensure the mount maintains originally marked position and install mount bolts Tighten bolts to 28 N m 250 in Ibs Fig 19 4 Install engine mount bracket Refer to proce dure in this section 5 Install bolt attaching right engine mount to bracket and tighten to 118 N m 87 ft Ibs Fig 18 6 Remove support from under engine 7 Install upper and lower engine torque struts Refer to procedure in this section 8 Install crankshaft damper Refer to procedure in this section 9 Install accessory drive belts Refer to Group 7 Cooling System for procedure ENGINE MOUNT BRACKET RIGHT REMOVAL 1 Remove upper and lower torque struts Refer to procedure in this section PL 2 Remove power steering air conditioning belt Refer to Group 7 Cooling System Accessory Drive Belts for procedure 3 Support engine with a suitable jack 4 Remove engine mount through bolt access plug Fig 20 5 Remove right engine mount to bracket through bolt Fig 21 6 Remove engine mount bracket attaching bolts Fig 22 7 Bracket removal requires engine to be raised slightly to obtain engine to body clearance 80be403 Fig 20 Engine Mount Bolt Access Plug 1 CRANKSHAFT BOLT ACCESS PLUG 2 RIGHT MOUNT BOLT ACCESS PLUG 3 FASCIA 4 SPLASH SHIELD
77. ining cyl inders 8 Compression should not be less than 689 kPa 100 psi and not vary more than 25 percent from cyl inder to cylinder 9 If one or more cylinders have abnormally low compression pressures repeat the compression test 10 If the same cylinder or cylinders repeat an abnormally low reading on the second compression test it could indicate the existence of a problem in the cylinder in question The recommended com pression pressures are to be used only as a guide to diagnosing engine problems An engine PL DIAGNOSIS AND TESTING Continued should not be disassembled to determine the cause of low compression unless some malfunc tion is present 11 Clean or replace spark plugs as necessary and adjust gap as specified in Group 8 Electrical Tighten to specifications 12 Test resistance of spark plug cables Refer to Group 8 Electrical Ignition System Secondary Cir cuit Inspection 13 Test coil output voltage primary and second ary resistance Replace parts as necessary Refer to Group 8 Electrical Ignition System 14 Check fuel pump pressure at idle and differ ent RPM ranges Refer to Group 14 Fuel System for Specifications 15 The air filter elements should be replaced as specified in Group 0 Lubrication and Maintenance 16 Inspect crankcase ventilation system as out lined in Group 0 Lubrication and Maintenance For emission controls see Group 25 Emission Controls for service procedure
78. ion 4 Remove crankshaft sprocket using Special Tool 6793 and insert C 4685 C2 Fig 84 5 Remove crankshaft sprocket key from crank shaft Fig 85 CAUTION Do not nick shaft seal surface or seal bore 80bbdad2 Fig 82 Bending Brace Structural Collar and Dust Cover 1 LATERAL BENDING BRACE 2 STRUCTURAL COLLAR 3 DUST COVER 2 Apply Mopar Silicone Rubber Adhesive Seal ant at the oil pump to engine block parting line Fig 83 3 Position a new oil pan gasket onto pan 4 Install oil pan and tighten screws to 12 Nm 105 in Ibs Fig 84 Crankshaft Sprocket Removal 5 Install transaxle dust cover Fig 82 1 SPECIAL TOOL 6793 6 Install lateral bending brace Fig 82 2 SPECIAL TOOL C 4685 C2 3 CRANKSHAFT SPROCKET PL REMOVAL AND INSTALLATION Continued 80bc4d2e Fig 85 Crankshaft Key 1 CRANKSHAFT KEY 6 Using Special Tool 6771 remove front crank shaft oil seal Fig 86 Do not damage the seal con tact area on the crankshaft 9409 196 Fig 86 Front Crankshaft Oil Seal Removal 1 SPECIAL TOOL 6771 2 0L SOHC ENGINE 9 49 9409 187 Fig 87 Front Crankshaft Oil Seal Installation 1 PROTECTOR 2 SEAL 3 SPECIAL TOOL 6780 1 4 INSTALLER INSTALLATION 1 Position seal into opening with seal spring towards the inside of engine Using Special Tool 6780 1 Fig 87 install seal until flush with cover 2 Instal
79. l crankshaft sprocket key Fig 85 3 Install crankshaft sprocket Fig 88 using Spe cial Tool 6792 NOTE Make sure the word front on the sprocket is facing outward NOTE Use of Special Tool 6792 is required to set proper crankshaft sprocket depth for proper timing belt tracking LZ D S 9509 73 h Fig 88 Crankshaft Sprocket Installation 1 SPECIAL TOOL 6792 9 50 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued 4 Install timing belt and cover Refer to proce dures in this section 5 Install crankshaft damper Refer to procedure in this section 6 Install accessory drive belts Refer to Group 7 Cooling System for procedure CRANKSHAFT OIL SEAL REAR REMOVAL 1 Remove transaxle Refer to Group 21 Tran saxle for procedure 2 Remove drive plate Refer to procedure in this section 3 Insert a 3 16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal Angle the screwdriver Fig 89 through the dust lip against metal case of the seal Pry out seal CAUTION Do not permit the screwdriver blade to contact crankshaft seal surface Contact of the screwdriver blade against crankshaft edge cham fer is permitted 806dc1b1 Fig 89 Rear Crankshaft Oil Seal Removal REAR CRANKSHAFT SEAL ENGINE BLOCK ENGINE BLOCK REAR CRANKSHAFT SEAL METAL CASE PRY IN THIS DIRECTION CRANKSHAFT SCREWDRIVER REAR CRANKSHAFT SEAL DUST LIP
80. le at the suspected leak area 3 If engine RPM S change the area of the sus pected leak has been found 4 Repair as required CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc tions Ensure the battery is completely charged and the engine starter motor is in good operating condition Otherwise the indicated compression pressures may not be valid for diagnosis purposes 1 Check engine oil level and add oil if necessary 2 Drive the vehicle until engine reaches normal operating temperature Select a route free from traf fic and other forms of congestion observe all traffic laws and accelerate through the gears several times briskly 3 Remove all spark plugs from engine As spark plugs are being removed check electrodes for abnor mal firing indicators fouled hot oily etc Record cyl inder number of spark plug for future reference 4 Disconnect coil wire from distributor and secure to good ground to prevent a spark from start ing a fire Conventional Ignition System For Direct Ignition System DIS disconnect the coil connector 5 Be sure throttle blade is fully open during the compression check 6 Insert compression gage adaptor into the 1 spark plug hole in cylinder head Crank engine until maximum pressure is reached on gage Record this pressure as 1 cylinder pressure 7 Repeat the previous step for all rema
81. manifold fasteners and washers are to be discarded and NEW fasteners and washers are to be used PL 80bc4d41 Fig 27 Brake Booster Hose 80bc4d40 Fig 28 PCV Hose 1 Install intake manifold onto cylinder head and tighten fasteners to 12 N m 105 in Ibs in sequence shown in Fig 32 PL REMOVAL AND INSTALLATION Continued NESE Dy Se A N ei LA gt N IR An LUN TSA va 80bo4ce0 gt Fig 29 MAP Sensor Fig 30 Knock Sensor 1 KNOCK SENSOR 2 STARTER MOTOR 2 0L SOHC ENGINE 9 29 80hc4d42 Fig 31 Intake Manifold Lower Supports 1 BOLT 2 BRACKET 3 BRACKET 4 BOLT 2 Install intake manifold to lower support bracket bolts Fig 31 Tighten bolts to 11 N m 95 in Ibs 3 Remove covering from fuel injector holes and insure the holes are clean Install fuel rail assembly to intake manifold Tighten screws to 23 N m 200 in Ibs 4 Connect PCV and brake booster hoses 5 Inspect quick connect fittings for damage replace if necessary Refer to Group 14 Fuel System for procedure Apply a light amount of clean engine oil to fuel inlet tube Connect fuel supply hose to fuel rail assembly Check connection by pulling on connec tor to insure it locked into position 6 Connect Manifold Absolute Pressure MAP Sensor wiring connector Fig 29 80bc4d2b Fig 32 Intake Manifold Tightening Sequence 7 Con
82. mbly 33 Remove the upper engine torque strut 34 Remove right and left engine and transaxle mount through bolts Fig 24 and Fig 25 35 Raise vehicle slowly until body is approxi mately 15 cm 6 in above normal engine mounting locations 36 Remove generator lower bracket and upper mounting bolt 37 Continue raising vehicle slowly until engine transaxle assembly clears engine compartment It may be necessary to move the engine transmission assembly with the cradle to allow for removal around body flanges 80bc4e9b Fig 24 Right Mount Through Bolt 1 BOLT 2 RIGHT ENGINE MOUNT 3 ENGINE MOUNT BRACKET INSTALLATION 1 Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine transaxle assembly until vehicle is within 15 cm 6 in of engine mounting locations 2 Install generator lower bracket and adjusting bolt 3 Continue lowering vehicle until engineftran saxle aligns to mounting locations Install mounting bolts at the right and left engine transaxle mounts Fig 24 and Fig 25 Tighten bolts to 118 N m 87 ft Ibs 4 Install upper engine torque strut Refer to pro cedure in this section 5 Remove safety straps from engine transaxle assembly Slowly raise vehicle enough to remove the engine dolly and cradle 6 Install axle shafts Refer to Group 3 Differen tial and Driveline for procedure 7 Install structural collar
83. mm 3 8 inch up from bottom of bore Refer to Engine Specifications in this section for cyl inder block specifications B FRONT A 10mm 3 8 IN J MIDDLE OF BORE 10 mm _ 3 8 IN USE FOR SIZING PISTON 9509 27 Fig 3 Checking Cylinder Bore Size SIZING PISTONS Piston and cylinder wall must be clean and dry Piston diameter should be measured 90 degrees to piston pin about 17 5 mm 11 16 inch from the bot tom of the skirt as shown in Fig 4 Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in Fig 3 Correct piston to bore clearance must be established in order to assure quiet and eco nomical operation Refer to Engine Specifications in this section for cylinder block and piston specifica tions DaimlerChrysler engines use pistons designed spe cifically for each engine model Clearance and sizing locations vary with respect to engine model PL SERVICE PROCEDURES Continued 9409 181 Fig 4 Piston Measurements 1 PISTON O D MEASUREMENT LOCATION NOTE Pistons and cylinder bores should be mea sured at normal room temperature 21 C 70 F FITTING PISTON RINGS 1 Wipe cylinder bore clean Insert ring and push down with piston to ensure it is square in bore The ring gap m
84. nect knock sensor connector and wiring at starter 8 Install inlet air duct to intake manifold and throttle body Tighten clamp to 3 N m 30 in Ibs 9 Connect negative cable to battery 10 With the DRB scan tool use ASD Fuel System Test to pressurize system to check for leaks 9 30 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued 80bc4c7e Fig 33 Intake Manifold Gaskets 1 INTAKE MANIFOLD O RING GASKETS CAUTION When using the ASD Fuel System Test the Auto Shutdown ASD relay will remain ener gized for 7 minutes or until the ignition switch is turned to the OFF position or Stop All Test is selected EXHAUST MANIFOLD REMOVAL 1 Disconnect negative cable from battery 2 Raise vehicle on hoist 3 Remove bolt attaching the wire harness heat shield to the exhaust manifold support bracket F ed eral and LEV Fig 34 or to the exhaust manifold ULEV 4 Remove exhaust manifold support bracket Federal and LEV Fig 35 5 Remove fasteners attaching exhaust system flex joint to exhaust manifold flange Move exhaust system rearward to clear flange studs 6 ULEV equipped remove the support bracket from cylinder block to exhaust manifold Fig 36 7 Lower vehicle 8 Disconnect CCV hose from rear of cylinder head cover 9 Disconnect oxygen sensor connector and har ness clip 10 Remove heat shield attaching bolts Fig 37 11 Remove upper heat s
85. nerally indicates seal leakage or crankshaft damage b Where leakage tends to run straight down possible causes are a porous block oil galley cup plug bedplate to cylinder block mating surfaces and seal bore See proper repair procedures for these items 4 If no leaks are detected pressurized the crank case as previously described CAUTION Do not exceed 20 6 kPa 3 psi 5 If the leak is not detected very slowly turn the crankshaft and watch for leakage If a leak is detected between the crankshaft and seal while slowly turning the crankshaft it is possible the crankshaft seal surface is damaged The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth CAUTION Use extreme caution when crankshaft polishing is necessary to remove minor nicks and scratches The crankshaft seal flange is especially machined to complement the function of the rear oil seal 6 For bubbles that remain steady with shaft rotation no further inspection can be done until dis assembled 7 After the oil leak root cause and appropriate corrective action have been identified refer to Crank shaft Oil Seal Rear for proper replacement proce dures PL DIAGNOSIS AND TESTING Continued ENGINE DIAGNOSIS PERFORM ANCE CONDITION POSSIBLE CAUSE ENGINE 9 11 CORRECTION ENGINE WILL NOT START 1 Weak battery 2 Corroded or loose battery connections Faulty starter
86. nifold Heat Shields 1 BOLTS 2 HEAT SHIELDS 7 Connect CCV hose on cylinder head cover port 8 Raise vehicle 9 Install new flex joint to manifold flange gasket 10 Attach exhaust system to manifold flange and tighten fasteners to 28 N m 250 in Ibs 11 Install exhaust manifold support bracket F ed eral and LEV Fig 35 Tighten M10 bolt to 54 N m 40 ft Ibs M12 bolt to 95 N m 70 ft Ibs and nut to 28 N m 250 in Ibs 12 ULEV equipped install support bracket to cylinder block and exhaust manifold Fig 36 Snug all bolts first then tighten to 54 N m 40 ft Ibs 13 Install bolt attaching wire harness heat shield to support bracket Federal and LEV Fig 34 or exhaust manifold ULEV 2 0L SOHC ENGINE 9 31 Fig 38 Exhaust Manifold Tightening Sequence 14 Lower vehicle 15 Connect negative cable to battery CYLINDER HEAD COVER REMOVAL 1 Disconnect CCV Fig 39 and PCV Fig 40 hoses from cylinder head cover 2 Remove ignition coil and spark plug cables Fig 41 3 Remove cylinder head cover bolts 4 Remove cylinder head cover 80b 4e5a Fig 39 CCV Hose INSTALLATION 1 Clean gaske surfaces Inspect gasket and seals Fig 42 Replace as necessary For replacement of spark plug tube seals refer to Spark Plug Tube Seals in this section for procedure CAUTION Do not attempt to loosen or remove baf fle plate attaching sc
87. nnecting rods are serviced as an assembly PISTON RINGS The piston rings include a molybdenum faced top ring for reliable compression sealing and a taper faced intermediate ring for additional cylinder pres sure control Oil Control Ring Package consist of two steel rails and an expander spacer CYLINDER HEAD The aluminum cylinder head features a Single Over Head Camshaft SOHC four valves per cylin der cross flow design The valves are arranged in two inline banks with the two intake per cylinder facing toward the radiator The exhaust valves facing toward the dash panel Rocker arm shafts mount directly to the cylinder head It incorporates powder metal valve guides and seats The hollow rocker arm shafts supplies oil to the hydraulic lash adjusters camshaft and valve mechanisms PL CAMSHAFT The nodular iron camshaft has five bearing jour nals and three cam lobes per cylinder Provision for a cam position sensor is provided on the camshaft at the rear of cylinder head which also acts as thrust plate A hydrodynamic oil seal is used for oil control at the front of the camshaft VALVES Four valves per cylinder are actuated by roller rocker arms hydraulic lash adjusters assemblies which pivot on rocker arm shafts All valves have chrome plated valve stems Viton rubber valve stem seals are integral with spring seats Valve springs spring retainers and locks are conventional design INTAKE MANIFOLD The intake manifol
88. nostic connector This connector is located in the passenger compartment at the lower edge of instrument panel near the steering column e Turn the ignition switch on and access the mis cellaneous screen e Select relearn cam crank option and follow directions on DRB screen PL CRANKSHAFT DAMPER REMOVAL 1 Remove accessory drive belts Refer to Group 7 Cooling System for procedure 2 Raise vehicle on a hoist and remove right inner splash shield 3 Remove crankshaft damper bolt Remove damper using the large side of Special Tool 1026 and insert 6827 A Fig 61 80387209 Fig 61 Crankshaft Damper Removal 1 SPECIAL TOOL 6827 A INSERT 2 SPECIAL TOOL 1026 THREE JAW PULLER INSTALLATION 1 Install crankshaft damper using M12 1 75 x 150 mm bolt washer thrust bearing and nut from Special Tool 6792 Fig 62 Fig 62 Crankshaft Damper tnstallation 1 M12 1 75 x 150 MM BOLT WASHER AND THRUST BEARING FROM SPECIAL TOOL 6792 PL REMOVAL AND INSTALLATION Continued 2 Install crankshaft damper bolt Using Special Tool 6847 and a torque wrench tighten bolt to 136 N m 100 ft Ibs Fig 63 3 Install accessory drive belts Refer to Group 7 Cooling System for procedure 4 Raise vehicle on hoist and install right inner splash shield 80bc4c80 Fig 63 Crankshaft Damper Bolt Tightening 1 SPECIAL TOOL 6847 2 CRANKSHAFT DAMPER TIMING BELT CO
89. ntact the scale the bolt s should be replaced CLEANING CYLINDER HEAD SEALING SURFACES CAUTION When cleaning cylinder head and cylin der block surfaces DO NOT use a metal scraper Sealing surfaces could be cut or ground resulting in gasket leaks Use only the cleaning methods shown in Fig 58 If required use a white 120 grit 3M Roloc bristle disk on aluminum surfaces A yellow 80 grit bristle disk can be used on cast iron surfaces with care 1 Clean the cylinder head and cylinder block sealing surfaces using a wood plastic scraper Apply solvent or a commercially available gasket remover to help soften the gasket residue If additional clean ing is required use a white 120 grit 3M Roloc bristle disk and a drill motor to remove gasket resi due PL REMOVAL AND INSTALLATION Continued 9509 70 Fig 56 Checking Cylinder Head Flatness 1 FEELER GAUGE 2 STRAIGHT EDGE i 0 d in NY INN 9009 38 Fig 57 Checking Bolts for Stretching Necking 1 STRETCHED BOLT 2 THREADS ARE NOT STRAIGHT ON LINE 3 THREADS ARE STRAIGHT ON LINE 4 UNSTRETCHED BOLT 2 Apply Mopar Gasket Sealant aerosol can to both sides of the new cylinder head gasket 3 Position a new cylinder head gasket on the locating dowels 4 Position crankshaft sprocket to TDC then rotate crankshaft until mark is three teeth before TDC Fig 59 This will ensure
90. nterweight adjacent to the bearing being checked PLASTIGAGE PROCEDURE 1 Remove oil film from surface to be checked Plastigage is soluble in oil 2 Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6 35 mm 1 4 in off center and away from the oil holes Fig 5 In addition suspected areas can be checked by placing the Plastigage in the suspected area Torque the bearing cap bolts of the bearing being checked to the proper specifications 3 Remove the bearing cap and compare the width of the flattened Plastigage Fig 6 with the metric scale provided on the package Locate the band clos est to the same width This band shows the amount of clearance in thousandths of a millimeter Differ ences in readings between the ends indicate the amount of taper present Record all readings taken Refer to Engine Specifications Plastigage gener ally is accompanied by two scales One scale is in inches the other is a metric scale NOTE Plastigage is available in a variety of clear ance ranges Use the most appropriate range for the specifications you are checking CONNECTING ROD BEARING CLEARANCE Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent The ENGINE 9 5 following is the recommended procedure for the use of Plastigage 1 Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke 2 Remove
91. of Plastigage NOTE The total clearance of the main bearings can only be determined by removing the weight of the crankshaft This can be accomplished by either of two methods PREFERRED METHOD Shim the bearings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft This can be accomplished by placing a minimum of 0 254 mm 0 010 in shim e g cardboard matchbook cover etc between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 14 20 N m 10 15 ft Ibs The number of main bear ing will vary from engine to engine ENGINE WITH 5 MAIN BEARINGS e When checking 1 main bearing shim main bearing e When checking 2 main bearing shim 1 amp 3 main bearing e When checking 83 main bearing shim 2 E A main bearing e When checking 4 main bearing shim amp 5 main bearing e When checking 5 main bearing shim 4 main bearing ENGINE WITH 4 MAIN BEARING e When checking 1 main bearing shim 2 main bearing PL GENERAL INFORMATION Continued e When checking 2 main bearing shim 1 amp main bearing e When checking 3 main bearing shim 2 amp 4 main bearing e When checking 4 main bearing shim main bearing NOTE REMOVE ALL SHIMS BEFORE REASSEM BLING ENGINE 9409 202 Fig 6 Clearance Measurement ALTERNATIVE METHOD The weight of the crankshaft can be supported by a jack under the cou
92. oil film from surface to be checked Plastigage is soluble in oil 3 Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approx imately 6 35 mm 1 4 in off center and away from the oil hole Fig 5 In addition suspect areas can be checked by placing plastigage in that area 4 Assemble the rod cap with Plastigage in place Tighten the rod cap to the specified torque Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared giving inac curate results 5 Remove the bearing cap and compare the width of the flattened Plastigage Fig 6 with the scale pro vided on the package Locate the band closest to the same width This band indicates the amount of oil clearance Differences in readings between the ends indicate the amount of taper present Record all readings taken Refer to Engine Specifications Plas tigage generally is accompanied by two scales One scale is in inches the other is a metric scale If the bearing clearance exceeds wear limit specification replace the bearing REPAIR OF DAMAGED OR WORN THREADS Damaged or worn threads including aluminum head spark plug threads can be repaired Essen tially this repair consists of drilling out worn or damaged threads tapping the hole with a special Heli Coil Tap or equivalent and installing an insert into the tapped hole This brings the hole back to its original thread size CAUTION Be sure th
93. olant All gauge pressure indications should be equal with no more than 25 leakage per cylinder FOR EXAMPLE At 552 kPa 80 psi input pres sure a minimum of 414 kPa 60 psi should be main tained in the cylinder LASH ADJUSTER TAPPET NOISE DIAGNOSIS A tappet like noise may be produced from several items Check the following items 1 Engine oil level too high or too low This may cause aerated oil to enter the adjusters and cause them to be spongy 2 Insufficient running time after rebuilding cylin der head Low speed running up to 1 hour may be required 3 During this time turn engine off and let set for a few minutes before restarting Repeat this several times after engine has reached normal operating temperature 4 Low oil pressure 5 The oil restrictor pressed into the vertical oil passage to the cylinder head is plugged with debris 6 Air ingested into oil due to broken or cracked oil pump pick up 7 Worn valve guides 8 Rocker arm ears contacting valve spring retainer 9 Rocker arm loose adjuster stuck or at maxi mum extension and still leaves lash in the system 10 Faulty lash adjuster a Check lash adjusters for sponginess while installed in cylinder head Depress part of rocker arm over adjuster Normal adjusters should feel very firm Spongy adjusters can be bottomed out easily b Remove suspected rocker arms sohc or lash adjuster dohc and replace ENGINE OIL LEAK INSPECTIO
94. or less Fig 129 or if the diameter is 79 95 mm 3 148 inches or less replace outer rotor 4 If inner rotor measures 7 64 mm 0 301 inch or less replace inner rotor Fig 130 9309 214 5 Slide outer rotor into pump housing press to one side with fingers and measure clearance between Fig 130 Measuring Inner Rotor Thickness rotor and housing Fig 131 If measurement is 0 39 PL CLEANING AND INSPECTION Continued mm 0 015 inch or more replace housing only if outer rotor is in specification Fig 131 Measuring Outer Rotor Clearance in Housing 1 FEELER GAUGE 2 OUTER ROTOR 6 Install inner rotor into pump housing If clear ance between inner and outer rotors Fig 132 is 0 203 mm 0 008 inch or more replace both rotors 9409 66 Fig 132 Measuring Clearance Between Rotors 1 FEELER GAUGE 2 INNER ROTOR 3 OUTER ROTOR 2 0L SOHC ENGINE 9 65 7 Place a straightedge across the face of the pump housing between bolt holes If a feeler gauge of 0 102 mm 0 004 inch or more can be inserted between rotors and the straightedge replace pump assembly Fig 133 ONLY if rotors are in specs Fig 133 Measuring Clearance Over Rotors 1 FEELER GAUGE 2 STRAIGHT EDGE 8 Inspect oil pressure relief valve plunger for scoring and free operation in its bore Small marks may be removed with 400 grit wet or dry sandpaper 9 The relief valve spring has a free leng
95. ount to the shafts for wear or dam age Replace if damaged or worn The rocker arm shaft is hollow and is used as a lubrication oil duct Check oil holes for clogging with small wire clean as required Lubricate the rocker arms and spacers Install onto shafts in their original position Fig 48 INSTALLATION CAUTION Set crankshaft to 3 notches before TDC before installing rocker arm shafts Refer to Timing Belt System and Camshaft Seal Service of this sec tion for procedure 1 Install rocker arm hydraulic lash adjuster assembly making sure that adjusters are at least partially full of oil This is indicated by little or no plunger travel when the lash adjuster is depressed If there is excessive plunger travel Place the rocker arm assembly into clean engine oil and pump the plunger until the lash adjuster travel is taken up If travel is not reduced replace the assembly Hydraulic lash adjuster and rocker arm are serviced as an assembly 2 0L SOHC ENGINE 9 35 9509 22 Fig 49 Rocker Arm Assemblies 1 EXHAUST ROCKER ARM 2 HYDRAULIC LASH ADJUSTERS 3 INTAKE ROCKER ARM 4 ROLLERS 2 Install rocker arm and shaft assemblies with NOTCH in the rocker arm shafts pointing up and toward the timing belt side of the engine Fig 50 Install the retainers in their original positions on the exhaust and intake shafts Fig 48 CAUTION When installing the intake rocker arm shaft assembly be sure that the plastic s
96. pacers do not interfere with the spark plug tubes If the spac ers do interfere rotate until they are at the proper angle To avoid damaging the spark plug tubes do not attempt rotating the spacers by forcing down the shaft assembly 3 Tighten bolts to 28 N m 250 in Ibs in sequence shown in Fig 51 7 gt N i as G j er Fig 50 Rocker Arm Shaft Notches 1 NOTCHES FACING UP AND TOWARD THE TIMING BELT SIDE OF THE ENGINE 4 Install cylinder head cover Refer to procedures in this section 9 36 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued 80bbdbd5 Fig 51 Rocker Arm Shaft Tightening Sequence HYDRAULIC LASH ADJUSTER NOISE A tappet like noise may be produced from several items Refer to Lash Adjuster Noise Diagnosis in Standard Service Procedures in this Group Lash adjusters are replaced with the rocker arm as an assembly VALVE SEALS AND SPRINGS IN VEHICLE REMOVAL 1 Remove rocker arm shafts assemblies Refer to procedure in this section 2 Rotate crankshaft until piston is at TDC on compression stroke 3 With air hose attached to adapter tool installed in spark plug hole apply 90 120 psi air pressure 4 Using Special Tool MD 998772A with adapter 6779 Fig 52 compress valve springs and remove x n om i ORT MR EA SS oe Be gt J j KAAR N g SJ SEM IS SN S ZW Ve SRE 2 ec SS N SI ee
97. r grease Using a proper driver drive plug into hole so that the sharp edge of the plug is at least 0 5 mm 0 020 inch inside the lead in chamfer Fig 3 It is not necessary to wait for curing of the sealant The cooling system can be refilled and the vehicle placed in service immediately ENGINE PERFORMANCE If a loss of performance is noticed timing belt or chain may have skipped one or two teeth Camshaft and crankshaft timing should be checked Refer to Group 9 Engine Timing belt or chain installation It is important that the vehicle is operating to it s optimum performance level to maintain fuel economy and lowest vehicle emissions If vehicle is not operat ENGINE 9 3 9209 41 Fig 3 Core Hole Plug Removal 1 CYLINDER BLOCK 2 REMOVE PLUG WITH PLIERS 3 STRIKE HERE WITH HAMMER 4 DRIFT PUNCH 5 CUP PLUG ing to these standards refer to Engine Diagnosis in this section The following procedures can assist in achieving the proper engine diagnosis 1 Test cranking amperage draw Refer to Group 8B Starting 2 Check intake manifold for vacuum leaks 3 Perform cylinder compression pressure test Refer to Engine Diagnosis in this section 4 Clean or replace spark plugs as necessary and adjust gap as specified in Group 8D Ignition System Tighten to specifications 5 Test resistance of spark plug cables Refer to Group 8D Ignition System 6 Test ignition coils primary and secondary resis
98. rews The screws are self tap ping and in the attempt to retighten thread damage stripping will result 9 32 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued ell Fig 40 PCV Valve Hose is L m nn 2 Ia ZTO 4 Les S Ss Bs QS Mi 3 S eg Be GC Go S a S A4 ALE wn0cdbe Fig 41 Ignition Coil and Spark Plug Cables 1 IGNITION COILS 2 SPARK PLUG CABLE 3 SPARK PLUG INSULATOR 2 Install cylinder head cover and gasket Tighten bolts to 12 N m 105 in Ibs 3 Install ignition coil and spark plug cables Fig 41 Tighten ignition coil fasteners to 12 N m 105 in Ibs 4 Connect CCV Fig 39 and PCV Fig 40 hoses SPARK PLUG TUBE SEALS The spark plug tube seals are located in the cylin der head cover Fig 43 These seals are pressed into the cylinder head cover to seal the outside perimeter of the spark plug tubes If these seals show signs of hardness and or cracking they should be replaced PL 80be4d2d Fig 42 Cylinder Head Cover Gasket and Seals 1 CYLINDER HEAD COVER GASKET 2 SEAL 3 BOLT 4 SPARK PLUG TUBE SEALS a SE 80524666 Fig 43 Spark Plug Tube Seals 1 SPARK PLUG TUBE SEAL 2 CYLINDER HEAD COVER REMOVAL 1 Remove cylinder head Refer to procedure in this section 2 Using an appropriate tool
99. rical connector Remove coil pack and spark plug cables from engine 30 Remove Crankcase Closed Ventilation CCV hose from cylinder head cover 31 Disconnect cam sensor and coolant tempera ture electrical connectors 32 Remove heater tube to cylinder head attach ing fasteners 33 Remove heater hose from thermostat housing connector 34 Remove cylinder head cover 35 Remove cylinder head bolts 36 Remove cylinder head and gasket Fig 55 9 38 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued PL 80bbe34a Fig 55 Cylinder Head Assembly 1 ROCKER SHAFT RETAINING BOLT 2 VALVE RETAINING LOCKS 3 VALVE 4 VALVE SPRING 5 VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY 6 SPARK PLUG TUBE SEAL 7 CAMSHAFT 8 ROCKER ARM SHAFT RETAINER SPACER 9 GASKET 10 SPACER 11 INTAKE ROCKER ARM HYDRAULIC LASH ADJUSTER ASSEMBLY 12 EXHAUST ROCKER ARM HYDRAULIC LASH ADJUSTER ASSEMBLY 13 CAMSHAFT SEAL 14 RETAINER SPACER 15 VALVE SPRING RETAINER NOTE Inspect camshaft bearing journals for scor ing Cylinder head must be flat within 0 1 mm 0 004 inch Fig 56 INSTALLATION EXAMINING CYLINDER HEAD BOLTS NOTE The cylinder head bolts should be examined BEFORE reuse If the threads are necked down the bolt s should be replaced Fig 57 Necking can be checked by holding a scale or straight edge against the threads If all the threads do not co
100. ring slots 4 Rings fitted too tightly in grooves 5 Worn valve guide s 6 Valve stem seal s worn or damaged 1 Check system and repair as necessary Refer to Group 25 Emission Control Systems 2 Hone cylinder bores Install new rings 3 Install new rings 4 Remove rings and check grooves If groove is not proper width replace piston 5 Ream guide s and replace valve s with oversize valve s and seal s 6 Replace seal s PL 2 0L SOHC ENGINE TABLE OF CONTENTS page DESCRIPTION AND OPERATION ENGINE IDENTIFICATION 15 ENGINE COMPONENTS 15 ENGINE LUBRICATION SYSTEM 17 DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE 18 SERVICE PROCEDURES CYLINDER BORE AND PISTON SIZING 18 FITTING PISTON RINGS 19 FITTING CONNECTING RODS 19 FITTING CRANKSHAFT BEARINGS 19 CRANKSHAFT END PLAY 20 REMOVAL AND INSTALLATION TORQUE STRUTS 0 000 20 ENGINE MOUNT LEFT 21 ENGINE MOUNT RIGHT 23 ENGINE MOUNT BRACKET RIGHT 24 STRUCTURAL COLLAR 2 2 22 25 ENGINE ASSEMBLY 25 INTAKE MANIFOLD 2 2222 2er 28 EXHAUST MANIFOLD 30 CYLINDER HEAD COVER 31 SPARK PLUG TUBE SEALS 32 SPARK PLUG TUBE iira c enesis aea a 33 CAMSHAFT E 04 MN na 33 ROCKER ARM HYDRAULIC LASH ADJUST
101. s 17 Inspect and adjust accessory belt drives refer ring to Group 7 Cooling System Accessory Drive Belts for proper adjustments 18 Road test vehicle as a final test CYLINDER COMBUSTION PRESSURE LEAKAGE TEST The combustion pressure leakage test provides an accurate means for determining engine condition Combustion pressure leakage testing will detect e Exhaust and intake valve leaks improper seat ing e Leaks between adjacent cylinders or into water jacket e Any causes for combustion compression pressure loss WARNING DO NOT REMOVE THE RADIATOR CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR Check the coolant level and fill as required DO NOT install the radiator cap Start and operate the engine until it attains nor mal operating temperature then turn the engine OFF Clean spark plug recesses with compressed air Remove the spark plugs Remove the oil filler cap Remove the air cleaner Calibrate the tester according to the manufactur er s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 ENGINE 9 9 kPa 200 psi maximum with 552 kPa 80 psi rec ommended Perform the test procedures on each cylinder according to the tester manufacturer s instructions While testing listen for pressurized air escaping through the throttle body tailpipe and oil filler cap opening Check for bubbles in the radiator co
102. stall order piston rings in the following Oil ring expander Upper oil ring side rail Lower oil ring side rail No 2 Intermediate piston ring No 1 Upper piston ring Install the side rail by placing one end between the piston ring groove and the expander Hold end firmly and press down the portion to be installed until side rail is in position Do not use a piston ring expander Fig 113 2 Install upper side rail first and then the lower side rail 3 Install No 2 piston ring and then No 1 piston ring Fig 112 4 Position piston ring end gaps as shown in Fig 114 mp Op Oo PL REMOVAL AND INSTALLATION Continued 80524822 Fig 112 Piston Ring Installation 1 NO 1 PISTON RING 2 NO 2 PISTON RING 3 SIDE RAIL 4 OIL RING 5 SPACER EXPANDER 9409 184 Fig 113 Installing Side Rail 1 SIDE RAIL END 5 Position oil ring expander gap at least 45 from the side rail gaps but not on the piston pin center or on the thrust direction Staggering ring gap is impor tant for oil control PISTON AND ROD INSTALLATION 1 Before installing pistons and connecting rod assemblies into the bore be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap 2 Before installing the ring compressor make sure the oil ring expander ends are butted and the rail gaps located as shown in Fig 114 3 Immerse the piston head and rings in
103. stud on the engine mount bracket point A and the center of the hole for the washer hose clip on the shock tower bracket point B is 119 mm 4 70 in Fig 12 4 With the engine held at the proper position tighten both the upper and lower torque strut bolts to 118 N m 87 ft Ibs Fig 10 5 Remove the floor jack ENGINE MOUNT LEFT REMOVAL 1 Raise vehicle approximately 30 5 cm 12 in on hoist 2 Remove air cleaner assembly Fig 13 Fig 11 Floor Jack Positioning 3 Remove battery and tray 1 WOOD BLOCK 4 Support transaxle with a suitable jack 2 FLOOR JACK 5 Remove left front wheel 6 Remove left splash shield 7 Remove through bolt access plug at left side outer frame rail 80bceast 9 22 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued BO a119 mm 80bceala Fig 12 Engine Position Measurement 8 Remove mount through bolt Fig 14 9 Disconnect transaxle shift cable from left mount and transaxle linkage 10 Remove left mount bracket to body frame rail fasteners Fig 15 11 Remove mount attaching bolts Fig 16 or Fig 17 12 Remove mount Fig 13 Air Cleaner Assembly 1 AIR CLEANER ASSY 2 THROTTLE BODY DUCT PL 80bbdad4 Fig 14 Left Mount Through Bolt 1 MOUNT BRACKET 2 BOLT 3 MOUNT 80bcesea Fig 15 Left Mount Bracket 1 MOUNT BRACKET 2 BODY FR
104. tand 7 Remove crankshaft damper timing belt and tensioner Refer to procedures in this section 8 Remove camshaft sprocket and rear timing belt cover Refer to procedures in this section 9 Remove crankshaft sprocket Refer to proce dure in this section compressor mounting bracket from engine Fig 95 11 Remove oil filter and adapter 12 Remove oil pan 13 Remove oil pump pick up tube 14 Remove oil pump 15 Remove crankshaft position sensor 16 Using a permanent ink or paint marker iden tify cylinder number on each connecting rod cap CAUTION DO NOT use a number stamp or a punch to mark connecting rods Damage to connecting rod could occur 17 Remove all connecting rod bolts and caps Care should be taken not to damage the fracture rod and cap surfaces PL REMOVAL AND INSTALLATION Continued Fig 95 Torque Strut Bracket 1 BOLTS 2 TORQUE STRUT BRACKET NOTE Do not reuse connecting rod bolts 18 Remove all main bearing cap and bedplate bolts from the engine block Fig 96 X INDICATES DOWEL LOCATION 80be4cb2 Fig 96 Bedplate Bolts 19 Using a mallet tap the bedplate loose from the engine block dowel pins CAUTION Do not pry up on one side of the bed plate Damage may occur to cylinder block and bed plate alignment 20 Bedplate should be removed evenly from the cylinder block dowel pins 21 Lift out crankshaft from cylinder block Fig 94 Be
105. th of approximately 60 7 mm 2 39 inches it should test between 18 and 19 pounds when compressed to 40 5 mm 1 60 inches Replace spring that fails to meet specifications 10 If oil pressure is low and pump is within spec ifications inspect for worn engine bearings damaged or missing oil pick up tube O ring clogged oil pick up tube screen clogged oil filter and stuck open pres sure relief valve or other reasons for oil pressure loss CYLINDER BLOCK AND BORE 1 Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking 2 If new core plugs are installed refer to Engine Core Plugs in this section 3 Examine block and cylinder bores for cracks or fractures 9 66 2 0L SOHC ENGINE CLEANING AND INSPECTION Continued CYLINDER BORE INSPECTION The cylinder walls should be checked for out of round and taper with Tool C 119 Fig 134 If the cyl inder walls are badly scuffed or scored the cylinder block should be rebored and honed and new pistons and rings fitted Whatever type of boring equipment is used boring and honing operation should be closely coordinated with the fitting of pistons and rings in order that specified clearances may be main tained Refer to Honing Cylinder Bores outlined in the Standard Service Procedures for specifi cation and procedures Measure the cylinder bore at three levels in direc tions A and B Fig 134 Top measurement should be 10 mm 3 8 in down and bot
106. tom measurement should be 10 mm 3 8 in up from bottom of bore For specifications refer to Engine Specifications in this section ADJ USTMENTS ENGINE TORQUE STRUT ADJUSTMENT The upper and lower torque struts need to be adjusted together to assure proper engine positioning and engine mount loading Whenever a torque strut bolt s is loosened this procedure must be performed 1 Loosen the upper and lower torque strut attaching bolt at the suspension crossmember and shock tower bracket Fig 135 2 The engine position may now be adjusted by positioning a suitable floor jack on the forward edge of the transmission bell housing Fig 136 NOTE The floor jack must be positioned as shown in Fig 136 to prevent minimal upward lifting of the engine PL B FRONT A 10mm 3 8 IN J MIDDLE OF BORE IO mm _ 3 8 IN USE FOR SIZING PISTON 9509 27 Fig 134 Checking Cylinder Bore Size 3 Carefully apply upward force allowing the upper engine to rotate rearward until the distance between the center of the rearmost attaching stud on the engine mount bracket point A and the center of the hole for the washer hose clip on the shock tower bracket point B is 119 mm 4 70 in Fig 137 4 With the engine held at the proper position tighten both the upper and lower torque strut bolts to 118 N m 87 ft Ibs Fig 135 5 Remove the floor jack 67 9 2 0L SOHC ENGI
107. valve proceed as follows 2 Remove the threaded plug and gasket from the oil pump Fig 116 CAUTION Oil pump pressure relief valve must be installed as shown in Fig 116 or serious damage may occur 3 Remove spring and relief valve Fig 116 9409 62 Fig 116 Oil Pressure Relief Valve 1 RETAINER CAP 2 GASKET 3 OIL PUMP BODY 4 RELIEF VALVE 5 SPRING 4 Remove oil pump cover screws and lift off cover 5 Remove pump rotors 6 Wash all parts in a suitable solvent and inspect carefully for damage or wear Fig 117 VALVE SERVICE WITH THE CYLINDER HEAD REMOVED REMOVAL 1 With cylinder head removed compress valve springs using Special Tool C 3422 B with Adaptor 6526 PL 9409 63 Fig 117 Oil Pump 1 OIL PUMP BODY 2 OIL PUMP COVER 3 OUTER ROTOR 4 INNER ROTOR 2 Remove valve retaining locks valve spring retainers valve stem seals and valve springs 3 Before removing valves remove any burrs from valve stem lock grooves to prevent dam age to the valve guides dentify valves to insure installation in original location VALVE INSPECTION 1 Clean valves thoroughly and discard burned warped and cracked valves 2 Measure valve stems for wear Measure stem about 60 mm beneath the valve lock grooves 3 If valve stems are worn more than 0 05 mm 0 002 in replace valve VALVE GUIDES 1 Remove carbon and varnish deposits from inside o
108. ystem for filling procedure 22 Install battery tray and battery 23 Install air cleaner housing assembly and con nect intake duct to intake manifold 2 0L SOHC ENGINE 9 27 l 1 Ok ULF XG PANG 4 eS A S Jm PS e N ZA d Wi O D 80bc4f02 Fig 26 Positioning Engine Cradle Support Post 1 SAFETY STRAPS 2 PLACE REAR POSTS INTO LOCATING HOLES 3 SPECIAL TOOL 6848 4 SPECIAL TOOL 6710 5 SPECIAL TOOL 6135 6 SAFETY STRAPS 7 PLACE FRONT POST UNDER BLOCK FLANGE 24 Connect all throttle body electrical connectors and linkage 25 Install oil filter Fill engine crankcase with proper oil to correct level 26 Perform camshaft and crankshaft timing relearn procedure as follows e Connect the DRB scan tool to the data link diagnostic connector This connector is located in the passenger compartment at the lower edge of instrument panel near the steering column e Turn the ignition switch on and access the mis cellaneous screen e Select relearn cam crank option and follow directions on DRB screen 9 28 2 0L SOHC ENGINE REMOVAL AND INSTALLATION Continued 27 Start engine and run until operating temper ature is reached 28 Ensure engine is properly positioned Refer to Torque Struts in this section for adjustment proce dure 29 Adjust transmission linkage if necessary INTA

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