Chrysler JA Cirrus Stratus 1997 Service Manual – Engine

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JA ENGINE 9 - 1

ENGINE

CONTENTS

page page

2.0L SOHC ENGINE ..................... 12

2.4L ENGINE .......................... 56

2.5L ENGINE .......................... 98

STANDARD SERVICE PROCEDURES

page page

GENERAL INFORMATION

CHECKING ENGINE OIL LEVEL ............. 5

ENGINE CORE PLUGS ................... 2

ENGINE OIL SERVICE .................... 5

ENGINE PERFORMANCE ................. 2

FORM-IN-PLACE GASKETS ................ 1

GENERAL INFORMATION

FORM-IN-PLACE GASKETS

There are numerous places where form-in-place

gaskets are used on the engine. Care must be taken when applying form-in-place gaskets. 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, a continuous bead of the proper width is essential to obtain a leak-free joint.

Two types of form-in-place gasket materials are used in the engine. Mopar Silicone Rubber Adhesive Sealant and Mopar Gasket Maker, (anaerobic) each have different properties and cannot be used interchangeably.

CAUTION: Silicone sealer and anaerobic sealers each will inhibit the cure of the other and care should be taken to keep usages separated as much as possible.

MOPAR SILICONE RUBBER ADHESIVE SEALANT

Mopar Silicone Rubber Adhesive Sealant or equivalent, normally black in color, is available in three

ENGINE DIAGNOSIS ...................... 7

STANDARD SERVICE PROCEDURES ......... 1

INDEX

HONING CYLINDER BORES ............... 3

HYDROSTATIC LOCKED ENGINE ........... 5

MEASURING MAIN BEARING AND

CONNECTING ROD BEARING

CLEARANCES ........................ 3

REPAIR OF DAMAGED OR WORN THREADS . . 5

ounce tubes. Moisture in the air causes the Mopar Silicone Rubber Adhesive Sealant material to cure. This material is normally used on flexible metal flanges. It has a shelf life of one year and will not properly cure if over age. Always inspect the package for the expiration date before use.

MOPAR GASKET MAKER

Mopar Gasket Maker is an anaerobic type gasket material normally red in color. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. It is normally red in color. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.

MOPAR TORQUE CURE GASKET MAKER

Mopar Torque Cure Gasket Maker is a unique anaerobic type gasket material to be used ONLY between the bedplate and engine block. The material cures in the absence of air when torqued between two metallic surfaces. It will not cure if left in the uncovered tube. This anaerobic material is specially made to seal the area between the bedplate and cylinder block without disturbing the bearing clearance or alignment of these components.

CYLINDERBLOCK SECOND REMOVE PLUGWITH PLIERSFIRST STRIKE HEREWITH HAMMERDRIFTCUP PLUG

9 - 2 ENGINE JA

GENERAL INFORMATION (Continued)

GASKET DISASSEMBLY

Parts assembled with form-in-place gaskets may be disassembled without unusual effort. In some instances, it may be necessary to lightly tap the part with a mallet or other suitable tool to break the seal between the mating surfaces. A flat gasket scraper may also be lightly tapped into the joint but care must be taken not to damage the mating surfaces.

SURFACE PREPARATION

Scrape clean or wire brush all gasket surfaces to remove all loose material. Inspect stamped parts to ensure gasket rails are flat. Flatten rails with a hammer on a flat plate if required. Gasket surfaces must be free of oil and dirt. Make sure old gasket material is removed from blind attaching holes.

FORM-IN-PLACE GASKET APPLICATION

Assembling parts using a form-in-place gasket requires care but it’s easier then using precut gaskets.

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 surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing the material off location.

The Mopar Silicone Rubber Adhesive Sealant gasket material or equivalent should be applied in a continuous bead approximately 3 mm (0.120 in.) 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 towels. 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 of material off location.

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. 1). With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug (Fig. 1).

CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems.

INSTALLATION

Thoroughly remove all rust and clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with sealer. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, 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. 1).

It is in 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, ignition timing should be checked. timing belt or chain may have skipped one or two teeth. Camshaft and crankshaft timing should also be checked. Refer to Group 9, Engine Timing belt or chain installation.

To provide best vehicle performance and lowest vehicle emissions, it is most important that the tune-up be done accurately. Use the specifications listed on the Vehicle Emission Control Information label found in the engine compartment.

(1) Test cranking amperage draw. See Starting Motor Cranking Amperage Draw Electrical Section of this manual.

(2) Check intake manifold for vacuum leaks.

PERFORM CYLINDER COMPRESSION TEST

(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 traffic 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-

Fig. 1 Core Hole Plug Removal

CROSS-HATCHPATTERN

JA ENGINE 9 - 3

GENERAL INFORMATION (Continued)

mal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference.

(4) Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting 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 remaining cylinders.

(8) Compression should not be less than (689kPa) 100 psi and not vary more than 25 percent from cylinder 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 should not be disassembled to determine the cause of low compression unless some malfunction is present.

(11) Clean or replace spark plugs as necessary and adjust gap as specified in Group 8, Electrical. Tighten to specifications.

(1) Test resistance of spark plug cables. Refer to

Group 8, Electrical Ignition System Secondary Circuit Inspection.

(2) Test coil output voltage, primary and secondary resistance. Replace parts as necessary. Refer to Group 8, Electrical Ignition System.

(3) Check fuel pump pressure at idle and different RPM ranges. Refer to Group 14, Fuel System for Specifications.

(4) The air filter elements should be replaced as specified in Group 0, Lubrication and Maintenance,.

(5) Inspect crankcase ventilation system as out lined in Group 0, Lubrication and Maintenance. For emission controls see Group 25, Emission Controls for service procedures.

(6) Inspect and adjust accessory belt drives referring to Group 7, Cooling System, Accessory Drive Belts for proper adjustments.

(7) Road test vehicle as a final test.

HONING CYLINDER BORES

(1) Used carefully, the cylinder bore resizing hone C-823 equipped with 220 grit stones, is the best tool for this job. 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 will clean up a bore and maintain the required limits.

(2) Deglazing of the cylinder walls may be done using a cylinder surfacing hone, Tool C-3501, equipped with 280 grit stones, if the cylinder bore is straight and round. 20-60 strokes depending on the bore condition, will be sufficient to provide a satisfactory surface. Inspect cylinder 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 most satisfactory for proper seating of rings (Fig. 2).

Fig. 2 Cylinder Bore Cross-Hatch Pattern

(4) A controlled hone motor speed between 200-300 RPM is necessary to obtain the proper crosshatch 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.

MEASURING MAIN BEARING AND CONNECTING ROD BEARING CLEARANCES

PLASTIGAGE METHOD

PLASTIGAGE

9 - 4 ENGINE JA

GENERAL INFORMATION (Continued)

NOTE: REMOVE ALL SHIMS BEFORE REASSEMBLING ENGINE

Fig. 3 Plastigage Placed in Lower Shell

Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use 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

Shimming 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. lbs.). The number of main bear-

ing will vary from engine to engine.

ENGINE WITH 5 MAIN BEARINGS

• When checking #1 main bearing shim #2 main

bearing.

• When checking #2 main bearing shim #1 & 3

main bearing.

• When checking #3 main bearing shim #2 & 4

main bearing.

• When checking #4 main bearing shim #3 & 5

main bearing.

• When checking #5 main bearing shim #4 main

bearing.

ENGINE WITH 4 MAIN BEARING

• When checking #1 main bearing shim # 2 main

bearing.

• When checking #2 main bearing shim #1 & #3

main bearing.

• When checking #3 main bearing shim #2 & #4

main bearing.

• When checking #4 main bearing shim #3 main

bearing.

ALTERNATIVE METHOD

The weight of the crankshaft can be supported by a jack under the counterweight 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. 3). (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. 4) with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences 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 clearance 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 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 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-

Fig. 4 Clearance Measurement

ENGINE OIL LEVEL DIP-STICK

JA ENGINE 9 - 5

GENERAL INFORMATION (Continued)

imately 6.35 mm (1/4 in.) off center and away from the oil hole (Fig. 3). In addition, suspect areas can be checked by placing plastigage in the suspect 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 inaccurate results.

(5) Remove the bearing cap and compare the width of the flattened Plastigage (Fig. 4) with the scale provided 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. Plastigage generally is accompa-

nied by two scales. One scale is in inches, the other is a metric scale. If the bearing clearance exceeds 0.076 mm (0.003 in.) replace bearing.

NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking.

REPAIR OF DAMAGED OR WORN THREADS

Damaged or worn threads (including aluminum head spark plug threads) can be repaired. Essentially, 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.

(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 occurring again.

CAUTION: Squirt approximately 1 teaspoon of oil into cylinders, rotate engine to lubricate the cylinder 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) Connect 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, 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. Add only when the level is at or below the ADD mark (Fig. 5).

CAUTION: Be sure that 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, these steps should be used.

CAUTION: Do Not Use Starter Motor To Rotate 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 any fluid that may possibly be in the cylinder under pressure.

Fig. 5 Oil Level

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 WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

ANTICIPATED TEMPERA-TURE RANGE BEFORENEXT OIL CHANGE

9 - 6 ENGINE JA

GENERAL INFORMATION (Continued)

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Service Grade Certified or an oil that conforms to the API Service Grade SH or SH/CD. MOPAR provides engine oils that conform to all of these service grades.

SAE VISCOSITY

An SAE viscosity grade is used to specify the viscosity of engine oil. SAE 30 specifies a single viscosity engine oil. Engine oils also have multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 6).

Fig. 6 Temperature/Engine Oil Viscosity

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for gasoline engines. They are designated as either ENERGY CONSERVING or ENERGY CONSERVING II.

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. 7).

ENGINE OIL CHANGE

Change engine oil at mileage and time intervals described in the Maintenance Schedule.

Fig. 7 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 Hoisting and Jacking 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 section.

(8) Install oil fill cap.

(9) Start engine and inspect for leaks.

(10) Stop engine and inspect oil level.

ENGINE OIL FILTER CHANGE

FILTER SPECIFICATION

All engines are equipped with a high quality fullflow, disposable type oil filter. Chrysler Corporation recommends a Mopar or equivalent oil filter be used.

OIL FILTER REMOVAL

Refer to Removal and Installation Section in Group 9, Engine for procedure.

USED ENGINE OIL DISPOSAL

Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above.

JA ENGINE 9 - 7

ENGINE DIAGNOSIS

INDEX

page page

DIAGNOSIS AND TESTING

CYLINDER COMBUSTION PRESSURE

LEAKAGE TEST ....................... 8

CYLINDER COMPRESSION PRESSURE TEST . 7

ENGINE DIAGNOSIS—MECHANICAL ........ 11

ENGINE DIAGNOSIS—PERFORMANCE ..... 10

DIAGNOSIS AND TESTING

GENERAL INFORMATION

Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine tune-ups.

These malfunctions may be classified as either mechanical (e.g., 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 diagnosis.

Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot 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 Bottle) at the suspected leak area.

(3) If a change in RPM’S, the area of the suspected leak has been found.

(4) Repair as required.

GENERAL INFORMATION ................. 7

INSPECTION (ENGINE OIL LEAKS IN

GENERAL) ........................... 8

INTAKE MANIFOLD LEAKAGE DIAGNOSIS .... 7

LASH ADJUSTER (TAPPET) NOISE

DIAGNOSIS .......................... 8

CYLINDER COMPRESSION PRESSURE TEST

The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.

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.

(3) Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference.

(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 remaining cylinders.

(8) Compression should not be less than (689kPa) 100 psi and not vary more than 25 percent from cylinder 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 should not be disassembled to determine the

9 - 8 ENGINE JA

DIAGNOSIS AND TESTING (Continued)

cause of low compression unless some malfunction 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 Circuit Inspection.

(13) Test coil output voltage, primary and secondary resistance. Replace parts as necessary. Refer to Group 8, Electrical Ignition System.

(14) Check fuel pump pressure at idle and different 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 procedures.

(17) Inspect and adjust accessory belt drives referring 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:

• Exhaust and intake valve leaks (improper seat-

ing).

• Leaks between adjacent cylinders or into water

jacket.

• 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 normal 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 manufacturer’s instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1 379 kPa (200 psi) maximum and 552 kPa (80 psi) recommended.

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 coolant.

All gauge pressure indications should be equal, with no more than 25% leakage.

FOR EXAMPLE: At 552 kPa (80 psi) input pressure, a minimum of 414 kPa (60 psi) should be maintained 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 cylinder 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 maximum 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 lash adjusters, and disassemble Do not reuse retainer caps . Do not interchange parts and make sure that care and cleanliness is exercised in the handling of parts.

c. Clean out dirt and varnish with solvent.

d. Reassemble with engine oil.

e. Check for sponginess.

f. If still spongy, replace with new adjuster.

INSPECTION (ENGINE OIL LEAKS IN GENERAL)

Begin with a through 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.

JA ENGINE 9 - 9

DIAGNOSIS AND TESTING (Continued)

(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 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 various speeds for approximately 24km (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:

(6) Disconnect the fresh air hose (makeup air) at the cylinder head cover and plug or cap the nipple on the cover.

(7) Remove the PCV valve hose from the cylinder head cover. Cap or plug the PCV valve nipple on the cover.

(8) Attach an air hose with pressure gauge and regulator to the dipstick tube.

CAUTION: Do not subject the engine assembly to more than 20.6 kpa (3 PSI) of test pressure.

(9) Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual

procedures.

(10) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.

(11) If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose. Proceed to next step.

(12) 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.

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 generally 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 outlined in the, Inspection (Engine oil Leaks in general)

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 disassembled.

(7) After the oil leak root cause and appropriate

corrective action have been identified. Refer to Rear Crankshaft Seals, for proper replacement procedures.

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 engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak.

9 - 10 ENGINE JA

DIAGNOSIS AND TESTING (Continued)

ENGINE DIAGNOSIS—PERFORMANCE

CONDITION POSSIBLE CAUSES CORRECTION

ENGINE WILL NOT START 1. Weak battery. 1. Test battery specific gravity. Charge or

2. Corroded or loose battery connections. 2. Clean and tighten battery connections.

3. Faulty starter. 3. Refer to Group 8A, Battery/Starter/

4. Moisture on ignition wires. 4. Wipe wires clean and dry.

5. Faulty ignition cables. 5. Replace any cracked or shorted cables.

6. Faulty coil or control unit. 6. Test and replace, if necessary (refer to

7. Incorrect spark plug gap. 7. Set gap (refer to Group 8D, Ignition

8. Dirt or water in fuel system. 8. Clean system and replace fuel filter.

9. Faulty fuel pump. 9. Install new fuel pump (refer to Group 14,

ENGINE STALLS OR ROUGH IDLE 1. Idle speed set too low. 1. Refer to Group 14, Fuel System.

2. Idle mixture too lean or too rich. 2. Refer to Group 14, Fuel System.

3. Leak in intake manifold. 3. Inspect intake manifold gasket and

4. Incorrect ignition wiring. 4. Install correct wiring.

5. Faulty coil. 5. Test and replace, if necessary (refer to

ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark plugs. 1. Clean plugs and set gap (refer to Group

2. Dirt or water in fuel system. 2. Clean system and replace fuel filter.

3. Faulty fuel pump. 3. Install new fuel pump.

4. Incorrect valve timing. 4. Correct valve timing.

5. Blown cylinder head gasket. 5. Install new cylinder head gasket.

6. Low compression. 6. Test compression of each cylinder.

7. Burned, warped or pitted valves. 7. Install new valves.

8. Plugged or restricted exhaust system. 8. Install new parts, as necessary.

9. Faulty ignition cables. 9. Replace any cracked or shorted cables.

10. Faulty coil. 10. Test and replace, as necessary (refer to

replace as necessary.

Apply a coat of light mineral grease to the terminals.

Charging System Diagnostics.

Group 8D, Ignition System).

System).

Fuel System).

vacuum hoses. Replace, if necessary (refer to Group 11), Exhaust System & Intake Manifold).

Group 8D, Ignition System).

8D, Ignition System).

Group 8D, Ignition System).

ENGINE MISSES ON ACCELERATION 1. Dirty or gap set too wide in spark plug. 1. Clean spark plugs and set gap (refer to

2. Dirt in fuel system. 2. Clean fuel system.

3. Burned, warped or pitted valves. 3. Install new valves.

4. Faulty coil. 4. Test and replace, if necessary (refer to

ENGINE MISSES AT HIGH SPEED 1. Dirty or gap set too wide in spark plug. 1. Clean spark plugs and set gap (refer to

2. Faulty coil. 2. Test and replace, as necessary (refer to

3. Dirty injector. 3. Clean injectors.

4. Dirt or water in fuel system. 4. Clean system and replace fuel filter.

Group 8D, Ignition System).

JA ENGINE 9 - 11

DIAGNOSIS AND TESTING (Continued)

ENGINE DIAGNOSIS—MECHANICAL

CONDITION POSSIBLE CAUSES CORRECTION

NOISY VALVES 1. High or low oil level in crankcase. 1. Checkfor correct oil level (refer to Group 0, Lubrication and

2. Thin or diluted oil. 2. Change oil (refer to Group 0, Lubrication and Maintenance.

3. Low oil pressure. 3. Check engine oil level.

4. Dirt in tappets/lash adjsuters. 4. Replace rocker arm/hydraulic lash adjuster assembly.

5. Worn rocker arms. 5. Inspect oil supply to rocker arms.

6. Worn tappets/lash adjusters. 6. Install new rocker arm/hydraulic lash adjuster assembly.

7. Worn valve guides. 7. Ream and install new valves with oversize stems.

8. Excessive runout of valve seats. 8. Grind valve seats and valves.

9. Missing adjuster pivot. 9. Replace rocker arm/hydraulic lash adjuster assembly.

CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level (refer to Group 0, Lubrication and

2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and

3. Thin or diluted oil. 3. Change oil to correct viscosity.

4. Excessive bearing clearance.

5. Connecting rod journal out-ofround.

6. Misaligned connecting rods. 6. Replace bent connecting rods.

MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level (refer to Group 0, Lubrication and

2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve.

3. Thin or diluted oil. 3. Change oil to correct viscosity.

4. Excessive bearing clearance. 4. Measure bearings for correct clearance. Repair as

5. Excessive end play. 5. Check thrust bearing for wear on flanges.

6. Crankshaft journal out-of-round, worn.

7. Loose flywheel or torque converter.

Maintenance).

Maintenance.

spring.

4. Measure bearings for correct clearance. Repair as necessary.

5. Replace crankshaft or grind journals.

Maintenance).

necessary.

6. Grind journals or replace crankshaft.

7. Tighten to correct torque.

OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.

OIL LEAKS

OIL CONSUMPTION OR SPARK PLUGS OIL FOULED

2. Faulty oil pressure sending unit. 2. Install new sending unit.

3. Low oil pressure. 3. Check sending unit and check main bearing oil clearance.

4. Clogged oil filter. 4. Install new oil filter.

5. Worn parts in oil pump. 5. Replace worn parts or pump.

6. Thin or diluted oil. 6. Change oil to correct viscosity.

7. Excessive bearing clearance. 7. Measure bearings for correct clearance.

8. Oil pump relief valve stuck. 8. Remove valve and inpsect, clean and install.

9. Oil pump suction tube loose, bent cracked, or blocked.

10. Oil pump cover warped or cracked.

1. Misaligned or deteriorated gaskets.

2. Loose fastener, broken or porous metal part.

3. Misaligned or deteriorated cup or threaded plug.

1. PCV system malfunction. 1. Check system. Clean and repair, as necessary (refer to

2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new rings.

3. Carbon in oil ring slot. 3. Install new rings.

4. Rings fitted too tightly in grooves. 4. Remove the rings. Check grooves. If groove is not proper

5. Worn valve guides. 5. Ream guides and replace valves with oversize valves and

6. Valve stem unseated or defective. 6. Repair or replace seal.

9. Remove oil pan and install new tube, or clean if necessary.

10. Install new oil pump.

1. Replace the gasket.

2. Tighten, repair or replace the part.

3. Replace.

Group 25, Emissions Control System).

width, replace piston.

seals.

ENGINE IDENTIFI-

CATION LOCATION

9 - 12 2.0L SOHC ENGINE JA

2.0L SOHC ENGINE

INDEX

page page

DESCRIPTION AND OPERATION

ENGINE COMPONENTS ................. 14

ENGINE IDENTIFICATION ................ 12

ENGINE LUBRICATION SYSTEM ........... 13

GENERAL SPECIFICATION ............... 12

DIAGNOSIS AND TESTING

CHECKING ENGINE OIL PRESSURE ........ 14

SERVICE PROCEDURES

CAMSHAFT END PLAY .................. 17

CRANKSHAFT END PLAY ................ 16

CYLINDER BORE AND PISTON SIZING ...... 15

FITTING CONNECTING RODS ............. 15

FITTING CRANKSHAFT BEARINGS ......... 16

FITTING PISTON RINGS ................. 15

REMOVAL AND INSTALLATION

CAMSHAFT OIL SEAL ................... 35

CAMSHAFT ........................... 22

CRANKSHAFT ......................... 38

CYLINDER HEAD COVER ................ 21

CYLINDER HEAD ....................... 25

ENGINE ASSEMBLY ..................... 19

ENGINE MOUNT—LEFT ................. 18

ENGINE MOUNT—RIGHT/ENGINE SUPPORT

BRACKET ........................... 18

ENGINE SUPPORT MODULE (FRONT AND

REAR MOUNTS) ...................... 18

FRONT CRANKSHAFT OIL SEAL ........... 36

OIL FILTER ADAPTER ................... 41

OILFILTER ........................... 41

OILPAN .............................. 34

OIL PUMP ............................ 41

PISTON AND CONNECTING ROD .......... 43

REAR CRANKSHAFT SEAL ............... 37

ROCKER ARM/HYDRAULIC LASH ADJUSTER . 23

SPARK PLUG TUBE ..................... 21

TIMING BELT COVER ................... 30

TIMING BELT .......................... 31

VALVE SEALS AND SPRINGS IN VEHICLE . . . 24 VALVE SERVICE WITH THE CYLINDER HEAD

REMOVED .......................... 26

VIBRATION DAMPER .................... 29

DISASSEMBLY AND ASSEMBLY

OIL PUMP ............................ 45

CLEANING AND INSPECTION

CYLINDER BLOCK AND BORE ............ 48

CYLINDER HEAD AND CAMSHAFT

JOURNALS .......................... 45

OIL PUMP ............................ 46

VALVE INSPECTION .................... 46

ADJUSTMENTS

ENGINE SUPPORT ADJUSTMENT .......... 49

SPECIFICATIONS

ENGINE 2.0L SOHC ..................... 50

TORQUE CHART 2.0L SOHC .............. 52

SPECIAL TOOLS

ENGINE 2.0L SOHC ..................... 53

DESCRIPTION AND OPERATION

ENGINE IDENTIFICATION

The engine identification number is located on the

left rear of the cylinder block behind starter (Fig. 1).

Fig. 1 Engine IdentificationSOHC

GENERAL SPECIFICATION

Type .............In-Line OHV, DOHC & SOHC

Bore .....................87.5mm (3.445 Inch)

Stroke ...................83.0mm (3.268 inch)

Compression Ratio ....DOHC - 9.6:1 SOHC - 9.8:1

Displacement .........2.0Liters (122 Cubic Inch)

Firing Order ........................1,3,4,2

Compression Pressure ...........1172-1551 kPa

(170 - 225 psi)

Maximum Variation Between Cylinders ......25%

Lubrication ...................Pressure Feed -

Full Flow Filtration

(Crankshaft Driven Pump)

Engine Oil Capacity

With Oil Filter Change .......4.25 Liter (4.5 Qts.)

Without Oil Filter Change .....3.8Liter (4.0 Qts.)

O-RINGOIL FILTER ADAPTEROIL PAN GASKETOIL PANOIL PICK-UP TUBEDRAIN PLUGO-RINGOIL PUMP BODYFILTERO-RINGNIPPLE

JA 2.0L SOHC ENGINE 9 - 13

DESCRIPTION AND OPERATION (Continued)

ENGINE LUBRICATION SYSTEM

route oil from main bearing journals to connecting

Engine Lubrication Components

ENGINE LUBRICATION

Refer to Group 0, Lubrication and Maintenance for recommended oil 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, supplying main and rod bearings with further routing. Rod bearing oil throwoff 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.

PRESSURE LUBRICATION

Oil drawn up through the pickup tube is pressurized by the pump and routed through the full flow filter to the main oil gallery running the length of the cylinder block. A cylinder head restrictor, located in the block, 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

Fig. 2 Engine Lubrication System—SOHC

rod journals.

9 - 14 2.0L SOHC ENGINE JA

DESCRIPTION AND OPERATION (Continued)

CAMSHAFT/HYDRAULIC LASH ADJUSTERS

A vertical hole at the number five bulkhead routes pressurized oil through a restrictor up into the cylinder head. The rocker shafts route oil to the rocker arms/hydraulic lash adjuster assemblies.

SPLASH LUBRICATION

Oil returning to the pan from pressurized components supplies lubrication to the valve stems. Cylinder bores and wrist pins are splash lubricated from directed slots on the connecting rod thrust collars.

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 incorporates main bearing caps. Rear seal retainer is integral with the block.

CRANKSHAFT A nodular cast iron crankshaft is used. The engine has 5 main bearings, with number 3 flanged to control thrust. The 52 mm diameter main and 48 mm diameter crank pin journals (all) have undercut fillet radiuses that are deep rolled for added strength. To optimize bearing loading 8 counterweights are used. Hydrodynamic seals provide end sealing, where the crankshaft 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 SOHC 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. All engines use pressed-in piston pins to attach forged powdered metal connecting 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 Connecting 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 pressure control. Oil Control Ring Package consist of 2 steel rails and a expander spacer.

CYLINDER HEAD — SOHC It features a Single Over Head Camshaft, four-valves per cylinder 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.

CAMSHAFT — SOHC The nodular iron camshaft has five bearing journals and 3 cam lobes per cylinder. Provision for cam position sensor on the cam 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 — SOHC Four valves per cylinder are actuated by roller rocker arms/hydraulic lash adjusters assemblies which pivot on rocker arm shafts. All valves have 6 mm diameter chrome plated valve stems. The valve train has 33 mm (1.299 inch) diameter intake valves and 28 mm (1.10 inch) diameter exhaust valves. Viton rubber valve stem seals are integral with spring seats. Valve springs, spring retainers, and locks are conventional design.

INTAKE MANIFOLD The intake manifold is a molded plastic composition, attached to the cylinder head with ten fasteners. This long branch design enhances low and midrange torque.

EXHAUST MANIFOLD The exhaust manifold is made of nodular cast iron for strength and high temperatures. Exhaust gasses exit through a machined, articulated joint connection to the exhaust pipe.

PARTS REPLACED

If any of the following parts have been changed or replaced:

• Camshaft

• Camshaft Position Sensor

• Camshaft Position Sensor Target Magnet

• Cylinder Block

• Cylinder Head

• Water Pump

• Powertrain Control Module (PCM)

• Timing belt and tensioner.

The camshaft and crankshaft timing relearn procedure must be performed. Refer to Group 25, for procedure.

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 perform the 3000 RPM test in the next step.

(3) Oil Pressure: Curb Idle 25 kPa (4 psi) minimum 3000 RPM 170-550 kPa (25-80 psi).

(4) If oil pressure is 0 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.

FRONT MIDDLEOF BORE

USE FOR SIZING

PISTON

PISTON O.D. MEASURE-MENT LOCATION

JA 2.0L SOHC ENGINE 9 - 15

SERVICE PROCEDURES

CYLINDER BORE AND PISTON SIZING

The cylinder walls should be checked for out-ofround and taper with Tool C-119 (Fig. 3). The cylinder bore out-of-round is 0.050 mm (.002 inch) maximum and cylinder bore taper is 0.051 mm (0.002 inch) maximum. If the cylinder 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 maintained. Refer to

Honing Cylinder Bores outlined in the Standard Service Procedures for specification and procedures.

Measure the cylinder bore at three levels in directions A and B (Fig. 3). Top measurement should be 10 mm (3/8 inch) down and bottom measurement should be 10 mm (3/8 inch.) up from bottom of bore. Refer to Cylinder Bore and Piston Specifications Table.

CYLINDER BORE AND PISTON

SPECIFICATIONS TABLE

Standard Bore Maximum

Out-of-Round

87.5 mm (3.445 in.)

0.051 mm (0.002 in.)

Maximum Taper

0.051 mm (0.002 in.)

Standard Piston Size

87.463 - 87.481 mm (3.4434 - 3.4441 in.)

Piston to Bore Clearance

0.012 - 0.044 mm (0.0004 - 0.0017 in.) Measurements Taken at Piston Size Location

be established in order to assure quiet and economical operation.

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 bottom 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). Refer to Cylinder Bore and Specifications Table. Correct piston to bore clearance must

Fig. 4 Piston Measurements

Chrysler engines use pistons designed specifically for each engine model. Clearance and sizing locations vary with respect to engine model.

NOTE: Pistons and cylinder bores should be measured 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 measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge (Fig. 5). Refer to specifications (Fig. 7).

(2) Check piston ring to groove side clearance (Fig.

6). Refer to specification (Fig. 7).

FITTING CONNECTING RODS

(1) Follow the procedure specified in the Standard Service Procedures Section for Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance (Fig. 8). Refer to specifications.

CAUTION: Do not rotate crankshaft or the Plastigage may be smeared.

FEELER GAUGE

9 - 16 2.0L SOHC ENGINE JA

SERVICE PROCEDURES (Continued)

Ring Position Ring Gap Wear Limit

Fig. 5 Piston Ring Gap

Upper Ring 0.23 to 0.52

mm (0.009 to 0.020 in.)

Intermediate Ring

Oil Control Ring

Ring Position Groove

Upper Ring 0.025 to 0.065

Intermediate Ring

OIL CONTROL RING - THREE PIECE. OIL RING SIDE RAILS MUST BE FREE TO ROTATE AFTER ASSEMBLY

0.049 to 0.78 mm (0.019 to 0.031 in.)

0.23 to 0.66 mm (0.009 to 0.025 in.)

Clearance

mm (0.0010 to

0.0026 in.)

0.025 to 0.065 mm (0.0010 to

0.0026 in.)

0.8 mm (0.031 in.)

1.0 mm (0.0039 in.)

Maximum Clearance

0.10 mm (0.004 in.)

Fig. 6 Piston Ring Side 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. lbs. PLUS 1/4 turn) Do not use a torque

wrench for last step.

(5) Using a feeler gauge, check connecting rod side clearance (Fig. 9). Refer to connecting rod specifications (Fig. 10).

FITTING CRANKSHAFT BEARINGS

Refer to Measuring Main Bearing Clearance in Standard Service Procedures. Refer to (Fig. 11) for specifications.

CRANKSHAFT END PLAY

DIAL INDICATOR METHOD

(1) Mount a dial indicator to front of engine, locating probe on nose of crankshaft (Fig. 12).

Fig. 7 Piston Ring Specifications

Fig. 8 Checking Connecting Rod Bearing Clearance

(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 and read the dial indicator. Refer to (Fig. 11) for specifications.

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-

JA 2.0L SOHC ENGINE 9 - 17

SERVICE PROCEDURES (Continued)

Fig. 9 Checking Connecting Rod Side Clearance

CONNECTING ROD BEARING OIL CLEARANCE

New Part: 0.026 to 0.059 mm

(0.001 to 0.0023 in.)

Wear Limit: 0.075 mm

(0.003 in.)

CONNECTING ROD SIDE CLEARANCE

New Part: 0.013 to 0.38mm

(0.005 to 0.015 in.)

Wear Limit: 0.40 mm

(0.016 in.)

Fig. 10 Connecting Rod Specifications

Fig. 12 Checking Crankshaft End Play—Dial

Indicator

age any bearing surface. Do not loosen main bearing cap.

(2) Use a feeler gauge between number three thrust bearing and machined crankshaft surface to determine end play.

CAMSHAFT END PLAY

(1) Oil camshaft journals and remove rocker arm assemblies. Cam sensor installed and fastener tighten to specified torque.

(2) Using a suitable tool, move camshaft as far rearward as it will go.

(3) Zero dial indicator (Fig. 13).

(4) Move camshaft as far forward as it will go.

(5) End play travel: 0.13 - 0.33 mm (0.005 - 0.013 inch.).

Fig. 11 Crankshaft Specifications

Fig. 13 Camshaft End Play

RIGHT ENGINE SUPPORTASSEMBLYFRAMERAIL 45 FT. LBS. (61 N·m) FWD

TORQUETRANSMISSIONSUPPORT ASSEM-BLYLEFT FRAMERAILGROUND CABLETRANSMISSIONBRACKETTRANSMISSIONFWD 61 N·m (45 ft. lbs.)33 N·m (24 ft. lbs.)

9 - 18 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION

ENGINE MOUNT—RIGHT/ENGINE SUPPORT BRACKET

NOTE: The right side engine mount is a HydroMount and may show surface cracks this will not effect it’s performance and should not be replaced. Only replace the Hydro-Mount when it’s leaking fluid.

(1) Raise vehicle on a hoist and remove inner splash shield. Remove the right engine support assembly vertical fasteners from frame rail (Fig. 14).

(2) Lower vehicle. Remove the load on the engine motor mounts by carefully supporting the engine assembly with a floor jack.

(3) Remove the three bolts attaching the engine support assembly to the engine bracket.

(4) Move the air conditioning dryer aside.

(5) Remove coolant recovery system tank. Refer to Group 7, Cooling System for procedure.

(6) Remove right engine support.

(7) Remove the three bolts attaching the engine support bracket to the cylinder block.

performance and should not be replaced. Only replace the Hydro-Mount when it’s leaking fluid.

(1) Support the transmission with a transmission

jack.

(2) Remove the three vertical bolts, from the

mount to the transmission.

(3) Remove the transmission mount fasteners and

remove mount.

(4) Reverse removal procedure for installation.

Refer to (Fig. 15) for bolt tightening specifications.

(5) Engine support assemblies adjustment, Refer to Engine Support Assembly Adjustment of this section.

NOTE: If centering or adjusting the engine/transmission assembly is needed refer to Adjustments, in this section.

(8) Reverse removal procedure for installation.

Refer to (Fig. 14) for torque specifications.

Fig. 14 Engine Mounting—Right Side

ENGINE MOUNT—LEFT

NOTE: If centering or adjusting the engine/transmission assembly is needed refer to Adjustments, in this section.

The left side engine mount is a Hydro-Mount and

may show surface cracks this will not effect it’s

Fig. 15 Engine Mounting—Left

ENGINE SUPPORT MODULE (FRONT AND REAR MOUNTS)

REMOVAL

(1) Raise vehicle on hoist.

(2) Remove thru bolt at rear mount and remove bolts attaching module to crossmember.

(3) Remove upper attaching bolt from rear support strut bracket (Fig. 16).

(4) Remove front attaching bolts from support module to lower radiator support.

(5) Support cooling module.

(6) Remove lower radiator support bolts, and remove support.

(7) Remove thru bolt at front mount and remove support module.

INSTALLATION

(1) Install thru bolt at front mount. Do not tighten at this time.

(2) Install lower radiator support.

(3) Install attaching bolts from support module to lower radiator support.

(4) Install upper bolt at rear support strut bracket.

LOWER RADIATOR SUP-PORTFRONT ENGINEMOUNTDAMPER WEIGHT (SOMEMODELS)ENGINE SUPPORT MODULEREAR ENGINEMOUNTREAR STRUT BRACKETSUPPORT BRACKET (SOMEMODELS)

TORQUEREAR TORQUE BRACKETENGINESTARTER WIRINGCLIP (2.5LENGINE)STRUTTRANSMISSIONSUPPORT 61 N·m (45 ft. lbs.)110 N·m (80 ft. lbs.)

FWD EXHAUST MANI-FOLDSTRUTPOWER STEERINGPUMPFWDSTRUT P/S BRACKETENGINE SUPPORTMODULEREAR MOUNTREAR TORQUE BRACKET

JA 2.0L SOHC ENGINE 9 - 19

REMOVAL AND INSTALLATION (Continued)

Fig. 16 Engine Support Module

(5) Install thru bolt at rear mount see (Fig. 17) or

(Fig. 18) tighten to 61 N·m (45 ft. lbs.).

(6) Tighten thru bolt at front mount see (Fig. 19)

tighten to 61 N·m (45 ft. lbs.).

Fig. 17 Engine Mounting—Rear 2.4 and2.5L

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. Set Powertrain Control Module (PCM) aside.

(3) Drain cooling system. Refer to Group 7, Cooling System for procedure.

(4) Remove upper radiator hose, radiator and fan module. Refer to Group 7, Cooling System for procedure.

(5) Remove lower radiator hose.

(6) Disconnect automatic transmission cooler lines and plug. If equipped.

Fig. 18 Engine Mounting—Rear 2.0L

(7) Disconnect clutch cable (Manual) and transmis-

sion shift linkage.

(8) Disconnect throttle body linkage. (9) Disconnect engine wiring harness. (10) Disconnect heater hoses. (11) Discharge Air Conditioning System. Refer to

Group 24, Air Conditioning for procedure.

(12) Hoist vehicle and remove right inner splash

shield (Fig. 20).

(13) Remove accessory drive belts. Refer to Group

7, Cooling System for procedure.

(14) Remove axle shafts. Refer to Group 2, Suspen-

sion and Driveshafts for procedure.

(15) Disconnect exhaust pipe from manifold. (16) Remove front engine mount. (17) Manual transmission: Remove power hop

damper.

(18) Lower vehicle. Remove air cleaner assembly. (19) Remove power steering pump and reservoir,

Set them aside.

(20) Remove A/C compressor.

ENGINE FWD FRONT TORQUEBRACKETFRONTMOUNTSTRUT (SOME MODELS)A/C COMPRESSORFWDSTRUT ENGINE SUPPORT MOD-ULE

NUT-SNAPPUSH-INFASTENERWHEELHOUSE SPLASHSHIELD FENDER FASCIAACCESSORY DRIVEBELT SPLASH SHIELDPUSH-IN FAS-TENER

PLACE FRONT SUP-PORT UNDERENGINE BLOCKFLANGE SPECIAL TOOLS6135 AND 6710PLACE REAR SUP-PORT POST INTOLOCATING HOLE INBEDPLATE

9 - 20 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

(23) Loosen engine support posts to allow movement 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. 21). Tighten mounts to cradle frame. This will keep support posts from moving when removing or installing engine and transmission.

(24) Install safety straps around the engine to cradle tighten; straps and lock them into position.

(25) Raise vehicle enough to see if straps are tight enough to hold cradle assembly to engine.

(26) Lower vehicle so weight of the engine and transmission ONLY is on the cradle assembly.

(27) Remove engine and transmission mount thrubolts.

(28) Raise vehicle slowly. It may be necessary to move the engine/transmission assembly with the cradle to allow for removal around body flanges.

Fig. 19 Engine Mounting—Front 2.0 and2.4L

Fig. 20 Right Inner Splash Shield

(21) Remove ground straps to body.

(22) Raise vehicle enough to allow engine dolly and cradle Special Tools 6135 and 6710 to be installed under vehicle.

Fig. 21 Positioning Engine Cradle SupportPost

Mounts

INSTALLATION

(1) Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine and transmission.

(2) Align engine and transmission mounts to attaching points. Install mounting bolts at the right engine and left transmission mounts. Refer to procedures outlined in this section.

(3) Remove safety straps from engine and transmission assembly. Slowly raise vehicle enough to remove the engine dolly and cradle.

(4) Install axle shafts. Refer to Group 2, Suspension and Driveshafts for procedure.

AIR INLET DUCT

IGNITIONCOILSSPARK PLUG CABLESPARK PLUGINSULATOR

JA 2.0L SOHC ENGINE 9 - 21

REMOVAL AND INSTALLATION (Continued)

(5) Install transmission and engine braces and

splash shields.

(6) Connect exhaust system to manifold. Refer to Group 11, Exhaust System and Intake Manifold for procedure and torque specifications.

(7) Install power steering pump and reservoir. Refer to Group 7, Cooling System Accessory Drive Section for belt tension adjustment.

(8) Install A/C compressor and hoses. Refer to Group 24, Heater and Air Conditioning for procedure.

(9) Install accessory drive belts. Refer to Group 7, Cooling System Accessory Drive Section for belt tension adjustment.

(10) Install front engine mount. Refer to this section for procedure.

(11) Manual transmission: Install power hop damper.

(12) Install inner splash shield. Install wheels and tires.

(13) Manual Transmission: Connect clutch cable and linkages. Refer to Group 6, Manual Transaxle Clutch.

(14) Automatic Transmission: Connect shifter and kickdown linkage. Refer to Group 21, Transaxle for procedures.

(15) Connect fuel line and heater hoses.

(16) Install ground straps. Connect engine and throttle body connections and harnesses. Refer to Group 8, Electrical for procedure.

(17) Connect throttle body linkage. Refer to Group 14, Fuel System for procedure.

(18) Install radiator and shroud assembly. Install

radiator hoses. Fill cooling system. Refer to Group 7, Cooling System for filling procedure.

(19) Install battery tray and battery. Set Powertrain Control Module (PCM) into place.

(20) Install air cleaner and hoses.

(21) Install oil filter. Fill engine crankcase with proper oil to correct level.

(22) Start engine and run until operating temperature is reached.

(23) Adjust transmission linkage, if necessary.

CYLINDER HEAD COVER

REMOVAL

(1) Remove air cleaner inlet duct (Fig. 22)

(2) Remove ignition coil pack (Fig. 23).

(3) Remove the cylinder head cover bolts.

(4) Remove cylinder head cover from cylinder head.

INSTALLATION

Before installation, clean cylinder head and cover mating surfaces. Make certain the cylinder head cover mating surface is flat.

(1) Install new valve cover gasket.

CAUTION: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping.

(2) Install cover assembly to head and tighten fas-

teners to 12 N·m (105 in. lbs.).

(3) Install ignition coil pack. Tighten fasteners to

23 N·m (200 in. lbs.).

SPARK PLUG TUBE

(1) Remove valve cover. Refer to procedure out-

lined in this section.

(2) Using locking pliers remove the tube from the

cylinder head (Fig. 24). Discard old tube.

(3) Clean area around spark plug with MOPAR

parts cleaner or equivalent.

(4) Apply Loctite sealer 271 or Mopar Stud and Bearing Mount or equivalent to a new tube approximately 1 mm from the end ina3mmwide area.

(5) Install sealer end of tube into the cylinder head. Then carefully install the tube using a hard-

Fig. 22 Inlet Duct Removal

Fig. 23 Ingition Coil Pack

SPARK PLUG TUBE SEALCYLINDER HEAD COVER

LOCKINGPLIERSSPARK PLUGTUBE

9 - 22 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

(3) Mark rocker arm shaft assemblies for installation.

(4) Remove rocker arm shaft bolts. Refer to procedure outlined in this section.

(5) Remove the timing belt and camshaft sprocket. Refer to timing belt service outlined in this section.

(6) Remove cylinder head. Refer to procedure outlined in this section.

(7) Remove camshaft sensor and remove camshaft from the rear of the head.

NOTE: Check oil feed holes for blockage.

Inspect cylinder head journals for wear, Refer to Cylinder Head, Inspect and Cleaning.

Check camshaft bearing journals for scratches and worn areas. If light scratches are present, they

Fig. 24 Servicing Spark Plug Tubes

wood block and mallet until the tube is seated into the bottom of the bore.

(6) Install valve cover. Refer to procedure outlined

in this section.

SPARK PLUG TUBE SEALS

The spark plug tube seals are located in the cylinder head cover (Fig. 25). These seals are pressed into the cylinder head cover to seal the end of the spark plug tubes. If these seals show signs of hardness and/or cracking they should be replaced.

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.

CAMSHAFT END PLAY

(1) Oil camshaft journals and install camshaft without rocker arm assemblies. Install cam sensor and tighten screws to specified torque.

(2) Using a suitable tool, move camshaft as far rearward as it will go.

(3) Zero dial indicator (Fig. 26).

(4) Move camshaft as far forward as it will go.

(5) End play travel: 0.13 - 0.33 mm (0.005 - 0.013 in.).

Fig. 25 Spark Plug Tube Seals

CAMSHAFT

NOTE: TO REMOVE CAMSHAFT CYLINDER HEAD MUST BE REMOVED.

REMOVAL

(1) Refer to Timing Belt Removal for timing belt

and camshaft sprocket removal and installation.

(2) Remove the cylinder head cover.

Fig. 26 Camshaft End Play

EXHAUST ROCKER ARM SHAFT

INTAKE ROCKER ARM SHAFT

EXHAUST ROCKER ARMASSEMBLYPLASTIC SHAFTSPACERSINTAKE ROCKER ARMASSEMBLYROCKER ARMSHAFT RETAINERS

EXHAUST ROCKER ARM HYDRAULIC LASHADJUSTERSINTAKE ROCKER ARMROLLER

JA 2.0L SOHC ENGINE 9 - 23

REMOVAL AND INSTALLATION (Continued)

INSTALLATION

(1) Lubricate camshaft journals. Install camshaft

into the cylinder head carefully.

(2) Install cam sensor and tighten fasteners to 9.5

N·m (85 in. lbs.).

(3) Install camshaft seal. Camshaft must be installed before the camshaft seal is installed. Refer to procedure outlined in this section.

(4) Install camshaft sprocket and tighten to 115 N·m (85 ft. lbs.).

(5) Install timing belt. (Refer to procedure outlined in this section).

(6) Install rocker arm assemblies in correct order as removed. Tighten the rocker arm assemblies in sequence shown in (Fig. 27) to 23 N·m (200 in. lbs.).

Fig. 27 Rocker Arm Shaft Tightening Sequence

ROCKER ARM/HYDRAULIC LASH ADJUSTER

REMOVAL

(1) Remove valve cover using procedure outlined 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 assemblies by removing the attaching bolts from the shaft (Fig. 28).

(5) Slide the rocker arms and spacers off the shaft. Keep the spacers and rocker arms in the same location for reassembly.

NOTE: Inspect the rocker arm for scoring, wear on the roller or damage to the rocker arm (Fig. 29) Replace if necessary. Check the location where the rocker arms mount to the shafts for wear or damage. 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

Fig. 28 Rocker Arm Shaft Assemblies

as required. Lubricate the rocker arms and spacers. Install onto shafts in their original position (Fig. 28).

Fig. 29 Rocker Arm Assemblies

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 section 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

NOTCHES FACING UP ANDTOWARD THE TIMING BELTSIDE OF THE ENGINE

EXHAUST ROCKER ARM SHAFT

INTAKE ROCKER ARM SHAFT

VALVE SPRING COMPRES-SOR SPECIAL TOOLMD-998772A ADAPTER6779AIR HOSE

VALVE SEAL TOOL VALVE STEM

9 - 24 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

lash adjuster and rocker arm are serviced as an assembly.

(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. 30). Install the retainers in their original positions on the exhaust and intake shafts (Fig. 28).

CAUTION: When installing the intake rocker arm shaft assembly be sure that the plastic spacers do not interfere with the spark plug tubes. If the spacers 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 23 N·m (200 in. lbs.) in sequence shown in (Fig. 31).

VALVE SEALS AND SPRINGS IN VEHICLE

REMOVAL

(1) Remove rocker arm shafts assemblies as previ-

ously outlined in this section.

(2) Rotate crankshaft until piston is at TDC on

compression.

(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. 32) compress valve springs and remove valve locks.

Fig. 30 Rocker Arm Shaft Notches

Fig. 31 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, outlined in this Group.

Lash adjusters are replaced with the rocker arm as an assembly.

Fig. 32 Removing and Installing Valve Spring

(5) Remove valve spring. (6) Remove valve stem seal by using a valve stem

seal tool (Fig. 33).

Fig. 33 Valve Stem Oil Seal Tool

INSTALLATION

(1) Install valve seal/valve spring seat assembly as outlined in the Valve Installation procedure in this section.

(2) Using Special Tool MD-998772A compress valve springs only enough to install locks. Correct alignment of tool is necessary to avoid nicking valve stems (air pressure required), piston at TDC

ROCKER SHAFT RETAINING

BOLT

VALVE RETAINING LOCKS VALVEVALVE SPRINGVALVE SEAL AND VALVESPRING SEAT ASSEMBLYROCKER ARM SHAFTRETAINER SPACERINTAKE ROCKER ARM/HYDRAULICLASH ADJUSTER ASSEMBLYCAMSHAFT SPACEREXHAUST ROCKER ARM/HY-DRAULIC LASH ADJUSTERASSEMBLY CAMSHAFT SEALSPARK PLUG TUBESEAL VALVE SPRING RETAINERRETAINER SPACER

VALVE RETAINING LOCKSVALVESPRINGVALVE SEAL ANDVALVE SPRING SEATASSEMBLYVALVE SPRINGRETAINER

JA 2.0L SOHC ENGINE 9 - 25

REMOVAL AND INSTALLATION (Continued)

(3) Install rocker

arm shaft assemblies as previously outlined in this section.

(4) Install valve cover as previously outlined in this section.

Fig. 34 Valve Spring Assembly

CYLINDER HEAD

Cylinder Head and Valve Assembly

AIR INLET DUCT

FEELERGAUGE STRAIGHTEDGE

9 - 26 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

REMOVAL

(1) Perform fuel system pressure release procedure before attempting any repairs. Refer to Group 14, Fuel System

(2) Disconnect negative battery cable. Drain cooling system. Refer to Group 7, Cooling System.

(3) Remove air cleaner inlet duct and air cleaner (Fig. 35), disconnect all vacuum lines, electrical wiring and fuel lines from throttle body.

Fig. 36 Checking Cylinder Head Flatness

(4.330 in.) are to be installed in positions 7, 8, 9, and 10 (Fig. 37).

(2) Tighten the cylinder head bolts in the sequence shown in (Fig. 37). Using the 4 step torque method, tighten according to the following values:

• First All to 34 N·m (25 ft. lbs.)

• Second All to 68 N·m (50 ft. lbs.)

• Third All to 68 N·m (50 ft. lbs.)

Fig. 35 Air Cleaner Inlet Duct

(4) Remove throttle linkage. (5) Remove accessory drive belts. Refer to Group 7,

Cooling System for procedure.

(6) Remove power brake vacuum hose from intake

manifold.

(7) Raise vehicle and remove exhaust pipe from

manifold.

(8) Remove power steering pump assembly and set

aside.

(9) Disconnect coil pack wiring connector and

remove coil pack and bracket from engine.

(10) Remove cylinder head cover. (11) Remove cam sensor and fuel injectors wiring

connectors.

(12) Remove intake manifold SOHC ONLY .

Removal procedure outline in Group 11.

(13) Remove timing belt and camshaft sprocket.

Refer to procedure outlined in this section.

(14) Remove rocker arm shaft assemblies. (15) Remove cylinder head bolts.

• Fourth Turn an additional 1/4 Turn, Do not use

a torque wrench for this step.

Fig. 37 Cylinder Head Tightening Sequence

For the rest of installation, reverse removal procedure.

NOTE: Inspect camshaft bearing journals for scoring. Cylinder head must be flat within 0.1 mm (0.004 inch) (Fig. 36).

INSTALLATION

(1) Before installing the bolts the threads should

be oiled with engine oil. The 4 short bolts 110 mm

VALVE SERVICE WITH THE CYLINDER HEAD REMOVED

REMOVAL

(1) With cylinder head removed, compress valve springs using Special Tool C-3422–B or equivalent.

(2) Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs.

TOPMIDDLEBOTTOM CUT AWAY VIEW OFVALVE GUIDE MEA-SUREMENT LOCA-TIONS

VALVE GUIDESPRING HEAT13.25 - 13.75 MM(.521 - .541 IN.)

TORQUE WRENCHVALVE SPRINGTESTER

JA 2.0L SOHC ENGINE 9 - 27

REMOVAL AND INSTALLATION (Continued)

(3) Before removing valves, remove any burrs

from valve stem lock grooves to prevent damage to the valve guides. Identify 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

(.002 in.), replace valve.

VALVE GUIDES

(1) Remove carbon and varnish deposits from

inside of 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 bottom (Fig. 38). Refer to (Fig. 39) for specifications. Replace guides if they are not within specification.

Place spring over stud on the table and lift compressing lever to set tone device (Fig. 41). Pull on torque 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. Fractional measurements are indicated on the table for finer adjustments. Discard the springs that do not meet specifications. The Following specifications apply to both intake and exhaust valve springs.

• Valve Closed Nominal Force— 67 lbs. @ 39.8 mm

(1.57 in.)

• Valve Open Nominal Force— 160 lbs. @ 32.6 mm

(1.28 in.)

Fig. 40 Valve Guide Height

Fig. 38 Checking Wear on Valve Guide—Typical

Fig. 39 Valve Guide Specifications

(3) Check valve guide height (Fig. 40).

TESTING VALVE SPRINGS

(1) Whenever valves have been removed for inspection, 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 inches). Turn tool table until surface is in line with the 33.34 mm (1-5/16 inch) mark on the threaded stud and the zero mark on the front.

Fig. 41 Testing a Valve Spring

(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 inch) out of square, install a new spring.

REFACING VALVES AND VALVE SEATS

(1) The intake and exhaust valve seats and valve face have a 45 degree angle.

VALVE FACEVALVE MARGIN

A — SEAT WIDTH (INTAKE AND EXHAUST 0.9 TO 1.3 mm (.035 TO .051IN.)B — FACE ANGLE (INTAKE & EXHAUST: 441⁄2°–45°)C — SEAT ANGLE (INTAKE & EXHAUST: 45°-451⁄2°)D — SEAT CONTACT AREAE — SEAT DIAMETER

9 - 28 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

(2) Inspect the remaining margin after the valves

are refaced (Fig. 42). Intake valves with less than

0.95 mm (1/32 inch.) margin and Exhaust valves with less than 1.05 mm (3/64 inch) margin should be discarded.

Fig. 42 Refacing Intake and Exhaust Valves

(3) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained See (Fig. 43) for valve specification.

valve face, contact is satisfactory. If the blue is transferred 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.

• Intake valve seat diameter is 33 mm (1.299 in.)

• Exhaust valve seat diameter is 28 mm (1.102

in.)

(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 serviced 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 to 1.25 mm (0.030 to 0.049 in.) (Fig. 44).

Fig. 43 Valve Specifications

(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 inch.) (total indicator reading).

(5) Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of

Fig. 44 Refacing Valve Seats

(8) Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip to 43.51 - 44.57 mm (1.71 - 1.75 in.) for exhaust valve and 45.01 - 46.07 mm (1.77 - 1.81 in.) for intake valve over spring seat when installed in the head (Fig. 45). 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. 46). The valve stem seals

GARTERSPRINGVALVESPRING SEAT CYLINDERHEAD SUR-FACE

VALVE SEAL TOOL VALVE STEM

NUT-SNAPPUSH-INFASTENERWHEELHOUSE SPLASHSHIELD FENDER FASCIAACCESSORY DRIVEBELT SPLASH SHIELDPUSH-IN FAS-TENER

JA 2.0L SOHC ENGINE 9 - 29

REMOVAL AND INSTALLATION (Continued)

(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.

Fig. 45 Checking Spring Installed Heightand Valve

Tip to Spring Seat Dimensions

should be pushed firmly and squarely over valve guide.

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. 46 Valve Stem Oil Seal Tool

(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.

VIBRATION DAMPER

REMOVAL

(1) Remove accessory drive belts. Refer to Group 7, Cooling System for procedure outlined in that section.

(2) Raise vehicle on a hoist and remove right inner splash shield (Fig. 47).

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 height B after refacing the valve and seat (Fig. 45). 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 a 0.762 mm (0.030 in.) spacer under the valve spring seat to bring spring height back within specification.

Fig. 47 Right Inner Splash Shield

SPECIALTOOL 6827–AINSERT SPECIAL TOOL1026

M12–1.75 x 150 MM BOLT,WASHER AND THRUSTBEARING FROM SPECIALTOOL 6792

ENGINE MOUNT BRACKET-TO-ENGINE FASTENERS

X — INDICATES RETAIN-ING CLIP LOCATIONFASTENERSACCESSPLUG

9 - 30 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

(3) Remove crankshaft damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827–A (Fig. 48).

Fig. 48 Crankshaft Damper—Removal

INSTALLATION

(1) 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 (105 ft. lbs.) (Fig. 49).

(2) Install accessory drive belts. Refer to Group 7, Cooling System Accessory Drive section for procedure.

(3) Raise vehicle on hoist and install right inner splash shield.

(3) Remove crankshaft vibration damper. Refer to

procedure outlined in this section for removal.

(4) Lower vehicle and place a jack under engine. (5) Remove right engine mount. Refer to procedure

outlined in this section.

(6) Remove right engine mount bracket (Fig. 50). (7) Remove front timing belt cover (Fig. 51).

Fig. 50 Right Engine Mount Bracket

Fig. 49 Crankshaft Damper—Installation

TIMING BELT COVER

REMOVAL

(1) Remove accessory drive belts. Refer to Group 7, Cooling System for procedure outlined in that section.

(2) Raise vehicle on a hoist and remove right inner splash shield (Fig. 47).

Fig. 51 Timing Belt Cover

INSTALLATION

(1) Install front timing cover. (2) Install engine mount bracket. (3) Install Right engine mount. Refer to procedure

outlined in this section for installation.

(4) Remove jack from under engine. (5) Install crankshaft vibration damper Refer to

procedure outlined in this section for installation.

ACCESS PLUG CAMSHAFT BOLT ANDWASHER CAMSHAFTSPROCKET REAR TIMING BELT COVERBRACKET WATER PUMPOIL PUMP BODYCRANKSHAFTSPROCKETTIMING BELT TENSIONERBOLTCRANKSHAFTDAMPERFRONT TIMING BELTCOVER

CAM SPROCKETTIMING MARK ARROW ONREAR COVER

JA 2.0L SOHC ENGINE 9 - 31

REMOVAL AND INSTALLATION (Continued)

Fig. 52 Timing Belt System

(6) Install accessory drive belts. Refer to Group 7, Cooling System Accessory Drive section for procedure.

(7) Raise vehicle on hoist and install right inner splash shield.

TIMING BELT

CHECKING BELT TIMING—COVER INSTALLED

• Remove number one spark plug.

• Using a dial indicator, set number one cylinder

to TDC on the compression stroke.

• Remove the access plug from the outer timing

belt cover (Fig. 52).

• Check the timing mark on the camshaft sprocket, it should align with the arrow on the rear belt cover (Fig. 53).

Fig. 53 Camshaft Timing Marks

SPECIALTOOL 1026 SPECIAL TOOL6827–A INSERT

NUT-SNAPPUSH-INFASTENERWHEELHOUSE SPLASHSHIELD FENDER FASCIAACCESSORY DRIVEBELT SPLASH SHIELDPUSH-IN FAS-TENER

ENGINE MOUNT BRACKET-TO-ENGINE FASTENERS

INDICATES RETAININGCLIP LOCATIONFASTENERSACCESSPLUG

9 - 32 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

REMOVAL—TIMING BELT

(1) Remove accessory drive belts. Refer to Group 7, Cooling System for procedure outlined in that section.

(2) Raise vehicle on a hoist and remove right inner splash shield (Fig. 54).

(4) Lower vehicle and place a jack under engine. (5) Remove right engine mount. Refer to procedure

outlined in this section.

(6) Remove right engine mount bracket (Fig. 56). (7) Remove front timing belt cover (Fig. 57).

CAUTION: Align camshaft and crankshaft timing marks before removing the timing belt.

(8) Loosen timing belt tensioner fasteners (Fig. 58)

and remove timing belt and tensioner.

Fig. 54 Right Inner Splash Shield

(3) Remove crankshaft damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827-A (Fig. 55).

Fig. 55 Crankshaft Damper—Removal

Fig. 56 Right Engine Mount Bracket—Typical

Fig. 57 Timing Belt Cover

TENSIONERPIVOTTIMING BELT TEN-SIONER TENSIONERFASTENERS

CAM SPROCKETTIMING MARK ARROW ONREAR COVER

TDCMARK

TENSIONER BENCH VISE (WITH SOFTJAWS)LOCKING PIN

JA 2.0L SOHC ENGINE 9 - 33

REMOVAL AND INSTALLATION (Continued)

Fig. 59 Compressing Timing Belt Tensioner

Fig. 58 Remove Timing Belt

CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND BELT INSTALLATION —SOHC ENGINE

(1) When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.

(2) Place the tensioner into a vise equipped with soft jaws and slowly compress the plunger (Fig. 59).

CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine.

(3) When plunger is compressed into the tensioner body install a 1.9 mm (5/64) allen wrench or pin through the body and plunger to retain plunger in place until tensioner is installed.

(4) 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. 60).

(5) Set camshaft to TDC by aligning mark on sprocket with the arrow on the rear of timing belt cover (Fig. 61).

(6) Move crankshaft to 1/2 mark before TDC (Fig.

62) for belt installation.

(7) Install timing belt. Starting at the crankshaft, go around the water pump sprocket and then around the camshaft sprocket.

(8) Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block but do not tighten fasteners.

Fig. 60 Crankshaft Sprocket Timing

Fig. 61 Camshaft Timing Mark

(9) Using a torque wrench on the tensioner pulley

apply 28 N·m (250 in. lbs.) of torque (Fig. 63).

(10) With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 N·m (275 in. lbs.) (Fig. 63).

(11) Pull tensioner plunger pin. Pretension is correct when pin can be removed and installed.

T.D.C.MARK T.D.C. REFER-ENCE MARK 1/2 NOTCH LOCATION

CAMSHAFTT.D.C. INSTALL TORQUEWRENCH HERECRANKSHAFT T.D.C.MOVE TEN-SIONER UP TOREMOVE CLEAR-ANCE

M12–1.75 3 150 MM BOLT,WASHER AND THRUSTBEARING FROM SPECIALTOOL 6792

PLACE A 1/8 INCH BEAD OFSEALER AT THE PARTING LINEOF THE OIL PUMP TO ENGINEBLOCK

9 - 34 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

(19) Raise vehicle on hoist and install right inner splash shield.

(20) Perform camshaft and crankshaft timing relearn. Refer to Group 25, Emission Control Systems for procedure.

Fig. 62 Adjusting Crankshaft Sprocket forTiming

Belt Installation

Fig. 63 Adjusting Timing Belt Tension

(12) Rotate crankshaft 2 revolutions and check the

alignment of the timing marks (Fig. 63).

(13) Install front half of timing cover. (14) Install engine mount bracket. (15) Install Right engine mount. Refer to proce-

dure outlined in this section.

(16) Remove jack from under engine.

(17) 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 (105 ft. lbs.) (Fig. 64).

(18) Install accessory drive belts. Refer to Group 7, Cooling System Accessory Drive section for procedure.

Fig. 64 Crankshaft Damper—Installation

OIL PAN

REMOVAL

(1) Drain engine oil.

(2) Remove transmission bending bracket. Refer to Engine Support Module Removal and Installation in this section.

(3) Remove front engine mount and bracket. Refer to Engine Support Module Removal and Installation in this section.

(4) Remove transmission inspection cover.

(5) If equipped with air conditioning remove oil filter and adaptor. Refer to Oil Filter Adapter Removal and Installation in this section.

(6) Remove oil pan.

(7) Clean oil pan and all gasket surfaces.

INSTALLATION

(1) Apply Mopar Silicone Rubber Adhesive Sealant or equivalent at the oil pump to engine block parting line (Fig. 65).

Fig. 65 Oil Pan Sealing

GRIND50.8 MM(2 INCHES)12.7 MM(1/2 INCH)

SPECIAL TOOLC-4679–A

SPECIAL TOOL MD998306

JA 2.0L SOHC ENGINE 9 - 35

REMOVAL AND INSTALLATION (Continued)

(2) Install a new oil pan gasket to pan. (3) Install pan and tighten screws to 12 N·m (105

in. lbs.).

(4) Install oil filter and adaptor. (5) Install transmission inspection cover. (6) install front engine mount and bracket. (7) Install transmission bending bracket.

(8) Install proper amount of oil. With oil filter 4.25 Liters (4.5 Qts.). Without oil filter 3.8 Liters (4.0 Qts.)

CAMSHAFT OIL SEAL

REMOVAL

CAUTION: Do Not Rotate the camshaft or crankshaft when timing belt is removed damage to the engine may occur.

(1) Remove timing belt cover and belt. Removal procedure is outlined in this section. Remove camshaft sprocket bolt, with the Modified Special Tool C-4687-1 as shown in (Fig. 66).

(2) Hold camshaft sprocket with modified tool while removing bolt. Remove sprocket from camshaft.

(3) Remove camshaft seal using Special Tool

C-4679–A (Fig. 67).

CAUTION: Do not nick shaft seal surface or seal bore.

(4) Shaft seal lip surface must be free of varnish,

dirt or nicks. Polish with 400 grit paper if necessary.

Fig. 67 Removing Camshaft Oil Seal

INSTALLATION

(1) Install camshaft seal flush with cylinder head

using Special Tool MD 998306 (Fig. 68).

Fig. 66 Modification to Special Tool

Fig. 68 Installing Camshaft Seal

(2) Install camshaft sprocket retaining bolt. Hold

camshaft sprocket with Special Tool C-4687-1 (Fig.

66) and tighten bolt to 115 N·m (85 ft. lbs.).

SPECIAL TOOL 6827 — AINSERTSPECIAL TOOL1026

SPECIAL TOOL 6793

PROTECTOR

SEAL

SPECIALTOOL6771

SPECIALTOOL6780–1INSTALLER

9 - 36 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

FRONT CRANKSHAFT OIL SEAL

REMOVAL

(1) Using Special Tool 1026 and Insert 6827–A, remove crankshaft damper (Fig. 69).

Fig. 69 Crankshaft Damper—Removal

(2) Remove outer timing belt cover and timing belt. Refer to Timing Belt System outlined in this section.

(3) Remove crankshaft sprocket using Special Tool 6793 and insert C- 4685-C2 (Fig. 70).

(4) Using Tool 6771 to remove front crankshaft oil seal (Fig. 71). Do not damage the seal contact area on the crankshaft.

Fig. 71 Front Crankshaft Oil Seal—Removal

INSTALLATION

(1) Install new seal by using Tool 6780–1 (Fig. 72).

(2) Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover.

CAUTION: Do not nick shaft seal surface or seal bore.

Fig. 70 Crankshaft Sprocket—Removal

Fig. 72 Front Crankshaft Oil Seal—Installation

M12 — 1.75 3 150 MM BOLT,WASHER AND THRUSTBEARING FROM SPECIALTOOL 6792

SPECIAL TOOL 6792

REAR CRANKSHAFTSEAL ENGINEBLOCK ENGINE BLOCKREAR CRANK-SHAFT SEALMETAL CASEPRY IN THISDIRECTIONCRANK-SHAFTSCREW-DRIVERREAR CRANKSHAFT SEALDUST LIPSCREW-DRIVER

JA 2.0L SOHC ENGINE 9 - 37

REMOVAL AND INSTALLATION (Continued)

(3) Install crankshaft sprocket (Fig. 73). Using

Special Tool 6792.

NOTE: Make sure the word “front” on the sprocket is facing you.

Fig. 73 Crankshaft Sprocket—Installation

(4) Install timing belt and covers. Refer to Timing

Belt System in this section for installation.

(5) Install crankshaft damper (Fig. 74). Use thrust bearing/washer and 12M-1.75 x 150 mm bolt from Special Tool 6792. Install crankshaft damper bolt and tighten to 142 N·m (105 ft. lbs.)

CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted.

Fig. 75 Rear Crankshaft Oil Seal—Removal

INSTALLATION

CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal.

Fig. 74 Crankshaft Damper—Installation

REAR CRANKSHAFT SEAL

REMOVAL

(1) Insert a 3/16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal. Angle the screwdriver (Fig. 75) through the dust lip against metal case of the seal. Pry out 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. 76).

(2) Position seal over pilot tool. Make sure you can read the words THIS SIDE OUT on seal (Fig. 76). Pilot tool should remain on crankshaft during installation 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. 77) until the tool bottoms out against the block (Fig. 78).

SPECIAL TOOL 6926–1PILOT SEAL

SPECIALTOOL6926–1PILOT

SPECIAL TOOL6792–2 INSTALLER

SEAL

SPECIALTOOL6926–2INSTALLER

9 - 38 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

Fig. 76 Rear Crankshaft Seal and SpecialTool 6926-1

Fig. 77 Crankshaft Seal Special Tool 6926-2

Fig. 78 Rear Crankshaft Seal—Installation

CRANKSHAFT

REMOVAL

(1) Remove oil filter and adapter from bedplate.

(2) Remove oil pan.

(3) Remove crankshaft sprocket and oil pump both procedures outlined in this section.

PISTON AND CONNECT-ING ROD ASSEMBLY SEAL OIL PASSAGEO-RINGSEALUPPER BEARING(GROOVED)THRUSTBEARINGSNIPPLEOIL FILTER ADAPTERO-RINGCRANKSHAFTPOSITION SEN-SOR (CPS) BOLTMAIN BEARING CAP/BED PLATE ASSEMBLYCONNECTING RODBEARINGS

FRONTOFENGINEINDICATES DOWEL LOCA-TION

JA 2.0L SOHC ENGINE 9 - 39

REMOVAL AND INSTALLATION (Continued)

(4) Remove all main bearing cap and bedplate

bolts from the engine block (Fig. 79).

Fig. 79 Bedplate Bolts

(5) Using a mallet tap the bedplate loose from the engine block dowel pins.

CAUTION: Do not pry up on one side of the bedplate. Damage may occur to cylinder block and bedplate alignment.

(6) Bedplate should be removed evenly from the cylinder block dowel pins.

(7) Lift out crankshaft from cylinder block. Be 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 (bedplate) main bearing cap are plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal (Fig. 80).

OIL GROOVES UPPERBEARINGSLOWERBEARINGSOIL HOLESFRONT

LUBRICATION GROOVESO-RING OIL HOLES

9 - 40 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

NOTE: The upper and lower main Bearing shells are Not interchangeable. The lower shells have a revised tab to prevent improper installation.

Fig. 81 Installing Main Bearing Upper Shell

CAUTION: Do Not get oil on the bedplate mating surface. It will affect the sealer ability to seal the

Fig. 80 Main Bearing Identification

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 .025 mm (.001 inch). Journal grinding should not exceed .305 mm (.012 inch) 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.

bedplate to cylinder block.

(3) Oil the bearings and journals and install

crankshaft and O-ring in cylinder block.

CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine.

(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of Mopar Torque Cure Gasket Maker to cylinder block as shown in (Fig. 82).

CAUTION: With the nodular cast iron crankshafts

used it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine.

Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Fig. 80). 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 (.0006 inch), .032 mm (.0012 inch), .250 mm (.010 inch). Never install an undersize bearing that will reduce clearance below specifications.

INSTALLATION

(1) Install the main bearing shells with the lubrication groove in the cylinder block. Install O-ring into recess in the block (Fig. 81).

(2) Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots.

Fig. 82 Main Bearing Caps/Bedplate Sealing

(5) Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. Install the main bearing/bedplate into engine block.

(6) Before installing the bolts the threads should be oiled 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 this bolts

O-RING

OIL FILTERADAPTER

LOCATING ROLL

FRONTOFENGINEINDICATES DOWEL LOCA-TION

OIL FILTER OIL FILTERWRENCHLOCATE WRENCH BAND ATBASE OF FILTER

JA 2.0L SOHC ENGINE 9 - 41

REMOVAL AND INSTALLATION (Continued)

down together until the bedplate contacts the cylinder block. Torque bolts to 30 N·m (22 ft. lbs.) (Fig.

83).

Fig. 83 Main Bearing Caps/Bedplate

TorqueSequence

(8) Install main bearing bedplate to engine block bolts (1 thru 10) and torque each bolt to 81 N·m (60 ft. lbs.) in sequence shown in (Fig. 83).

(9) Install main bearing bedplate to engine block bolts (11 thru 20), with baffle studs in positions 12, 13 and 16 and torque each bolt to 30 N·m (22 ft. lbs.) in sequence shown in (Fig. 83).

(10) After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 N·m (50 in. lbs.).

(11) Install oil pump. If crankshaft end play is to

be checked refer to service procedures in this section.

(12) Install crankshaft sprocket.

(13) Install oil filter adapter and filter. Refer to procedure outlined in this section.

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. lbs.) (Fig. 84).

OIL FILTER

REMOVE AND INSTALL

CAUTION: When servicing the oil filter (Fig. 85) avoid deforming the filter, install tool band strap against the seam at the base of the filter. The seam, joining the can to the base is reinforced by the base plate.

(1) Turn counterclockwise to remove.

(2) To install, lubricate new filter gasket. Check filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. Screw filter on until gasket contacts base. Tighten to 21 N·m (15 ft. lbs.).

Fig. 85 Engine Oil Filter

OIL PUMP

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove Timing Belt. Refer to Timing Belt System, in this section.

(3) Remove Oil Pan. Refer to Oil Pan Removal in this section.

Fig. 84 Engine Oil Filter Adapter to EngineBlock

SPECIAL TOOL6827–A INSERTSPECIALTOOL1026

SPECIAL TOOL 6793

9 - 42 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

(4) Remove Crankshaft Sprocket using Special Tool

6793 and insert C4685–C2 (Fig. 86).

Fig. 86 Crankshaft Sprocket—Removal

(5) Remove oil pick-up tube.

(6) Remove oil pump, (Fig. 87) and front crankshaft seal.

INSTALLATION

(1) Make sure all surfaces are clean and free of oil and dirt.

Fig. 87 Oil Pump and Tube

APPLY GASKETMAKER TO OILPUMP BODYFLANGE O-RING

PROTECTOR

SEAL

SPECIALTOOL6780–1INSTALLER

SPECIAL TOOL 6792TIGHTEN NUT TO INSTALL

WEIGHT DESIGNATION ANDDIRECTIONAL ARROW WILLBE IMPRINTED IN THISAREA

JA 2.0L SOHC ENGINE 9 - 43

REMOVAL AND INSTALLATION (Continued)

(2) Apply Mopar Gasket Maker to oil pump as shown in (Fig. 88). Install oil ring into oil pump body discharge passage.

Fig. 88 Oil Pump Sealing

(3) Prime oil pump before installation.

(4) Align oil pump rotor flats with flats on crankshaft 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. lbs.)

(6) Install new front crankshaft seal using Special Tool 6780 (Fig. 89).

Fig. 90 Crankshaft Sprocket—Installation

PISTON AND CONNECTING ROD

REMOVAL

(1) Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation . Mark piston with matching cylinder number (Fig. 91).

Fig. 89 Front Crankshaft Seal—Installation

(7) Install crankshaft sprocket, using Special Tool

6792 (Fig. 90).

(8) Install oil pump pick-up tube and oil pan. (9) Install Timing Belt. Refer to Timing Belt

Installation in this section.

Fig. 91 Piston Markings

(2) Remove oil pan. Scribe the cylinder number on the side of the rod and cap (Fig. 92) for identification.

Fig. 92 Identify Connecting Rod to Cylinder

NO. 1 PISTON RINGNO. 2 PISTON RING SIDE RAILOIL RINGSPACEREXPANDER

SIDE RAIL END

9 - 44 2.0L SOHC ENGINE JA

REMOVAL AND INSTALLATION (Continued)

(3) Pistons will have a stamping in the approximate location shown in (Fig. 91). These stamps will be either a directional arrow or a weight identification 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 production assemblies. The weight designation stamps should face toward the timing belt side of the engine.

(4) Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore.

(5) Remove connecting rod cap bolts Do not use old bolts if reinstalling connecting rod. Push each piston and rod assembly out of cylinder bore.

NOTE: Be careful not to nick crankshaft journals.

(6) After removal, install bearing cap on the mating rod.

(7) Piston and Rods are serviced as an assembly.

PISTON RING—REMOVAL

(1) ID 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. 93).

Fig. 94 Piston Ring Installation

c. Lower oil ring side rail. d. No. 2 Intermediate piston ring. e. No. 1 Upper piston ring.

f. 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. 95).

Fig. 93 Piston Rings—Removing and Installing

(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 I.D. mark fac-

ing up, to the top of the piston (Fig. 94).

CAUTION: Install piston rings in the following order:

a. Oil ring expander. b. Upper oil ring side rail.

Fig. 95 Installing Side Rail

(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. 94).

(4) Position piston ring end gaps as shown in (Fig.

96).

(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 important for oil control.

GAP OF LOWERSIDE RAIL NO. 1 RING GAPGAP OF UPPERSIDE RAILNO. 2 RING GAP ANDSPACER EXPANDERGAP FRONT OF ENGINE

RETAINER CAP GASKETOIL PUMP BODYRELIEFVALVESPRING

JA 2.0L SOHC ENGINE 9 - 45

REMOVAL AND INSTALLATION (Continued)

(6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.

(7) Install rod caps. Install New bolts and tighten to 27 N·m (20 ft.lb.) Plus 1/4 turn.

DISASSEMBLY AND ASSEMBLY

OIL PUMP

(1) To remove the relief valve, proceed as follows:

(2) Remove the threaded plug and gasket from the oil pump (Fig. 98).

CAUTION: Oil pump pressure relief valve must be installed as shown in (Fig. 98) or serious damage

Fig. 96 Piston Ring End Gap Position

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. 96).

(3) Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston (Fig. 97). Be sure position of rings does not change during this operation .

may occur.

(3) Remove spring and relief valve (Fig. 98).

Fig. 97 Installing Piston

(4) The weight stamp designation L or H will be in the front half of the piston should face toward the front of the engine for SOHC engine. The arrow should face toward the front of the engine for DOHC engine (Fig. 91).

(5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal.

Fig. 98 Oil Pressure Relief Valve

(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. 99).

CLEANING AND INSPECTION

CYLINDER HEAD AND CAMSHAFT JOURNALS

INSPECTING CYLINDER HEAD

Cylinder head must be flat within 0.1 mm (0.004

inch) (Fig. 100).

Inspect cylinder head journals for wear.

Check 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 cylinder head for damage. Replace the cylinder head if worn or damaged. Check the lobes for pitting and

FEELERGAUGE STRAIGHTEDGE

OIL PUMPBODYOIL PUMP COVEROUTERROTOR INNER ROTOR

TORQUE WRENCHVALVE SPRINGTESTER

9 - 46 2.0L SOHC ENGINE JA

CLEANING AND INSPECTION (Continued)

CLEANING

Clean all valve guides, valves and valve spring assemblies thoroughly with suitable cleaning solution before reassembling.

TESTING VALVE SPRINGS

(1) Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example, the compression length of the spring to be tested is 33.34 mm (15/16 inches). Turn tool table until surface is in line with the 33.34 mm (15/16 inch) 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. 101). Pull on torque wrench until ping is heard. Take reading on torque wrench at this

Fig. 99 Oil Pump

instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Discard the springs that do not meet specifications. The Following specifications apply to both intake and exhaust evolve springs;

• Valve Closed Nominal Tension— 58 ft. lbs. @

38.0 mm (1.50 in.)

• Valve Open Nominal Tension— 130 ft. lbs. @

29.75 mm (1.17 in.)

Fig. 100 Checking Cylinder Head Flatness

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.

CLEANING

Remove all gasket material from cylinder head and block. Be careful not to gouge or scratch the aluminum head sealing surface.

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 inch.), replace valve.

Fig. 101 Testing Valve Springs

(2) Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring.

OIL PUMP

(1) Clean all parts thoroughly. Mating surface of the oil pump should be smooth. Replace pump cover if scratched or grooved.

EXHAUST VALVE MARGINFACESTEM VALVESPRINGRETAINERLOCKGROOVE INTAKEVALVE

OIL PUMPBODYOIL PUMP COVEROUTERROTOR INNER ROTOR

JA 2.0L SOHC ENGINE 9 - 47

CLEANING AND INSPECTION (Continued)

Intake and Exhaust Valves

Valve Specifications

(2) Lay a straightedge across the pump cover surface (Fig. 102). If a 0.076 mm (0.003 inch.) feeler gauge can be inserted between cover and straight edge, cover should be replaced.

Fig. 102 Checking Oil Pump Cover Flatness

(3) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 7.64 mm (0.301 inch.) or less (Fig. 103), or if the diameter is 79.95 mm (3.148 inches) or less, replace outer rotor.

Fig. 103 Measuring Outer Rotor Thickness

(4) If inner rotor measures 7.64 mm (.301 inch) or less replace inner rotor (Fig. 104).

Fig. 104 Measuring Inner Rotor Thickness

FEELERGAUGE INNER ROTOROUTER ROTOR

FEELER GAUGEOUTER ROTOR

FEELERGAUGESTRAIGHTEDGE

9 - 48 2.0L SOHC ENGINE JA

CLEANING AND INSPECTION (Continued)

(5) Slide outer rotor into pump housing, press to one side with fingers and measure clearance between rotor and housing (Fig. 105). If measurement is 0.39 mm (0.015 inch.) or more, replace housing only if outer rotor is in specification.

Fig. 105 Measuring Outer Rotor Clearance

inHousing

(6) Install inner rotor into pump housing. If clearance between inner and outer rotors (Fig. 106) is .203 mm (.008 inch) or more, replace both rotors.

(7) Place a straightedge across the face of the pump housing, between bolt holes. If a feeler gauge of .102 mm (.004 inch) or more can be inserted between rotors and the straightedge, replace pump assembly (Fig. 107). ONLY if rotors are in specs.

Fig. 107 Measuring Clearance Over Rotors

(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 length 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 specifications, 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 pressure relief valve or other reasons for oil pressure loss.

Fig. 106 Measuring Clearance Between Rotors

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 outlined in this section.

(3) Examine block and cylinder bores for cracks or fractures.

CYLINDER BORE INSPECTION

The cylinder walls should be checked for out-ofround and taper with Tool C-119 (Fig. 108). The cylinder bore out-of-round is 0.050 mm (.002 inch) maximum and cylinder bore taper is 0.051 mm (0.002 inch) maximum. If the cylinder 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

FRONT MIDDLEOF BORE

USE FOR SIZING

PISTON

JA 2.0L SOHC ENGINE 9 - 49

CLEANING AND INSPECTION (Continued)

specified clearances may be maintained. Refer to Honing Cylinder Bores outlined in the Standard Service Procedures for specification and procedures.

Measure the cylinder bore at three levels in directions A and B (Fig. 108). Top measurement should be 10 mm (3/8 inch) down and bottom measurement should be 10 mm (3/8 inch.) up from bottom of bore. Refer to (Fig. 109) for specifications.

Fig. 108 Checking Cylinder Bore Size

ADJUSTMENTS

ENGINE SUPPORT ADJUSTMENT

The right and left support assemblies are slotted to allow for right/left drive train adjustment in relation to drive shaft assembly length.

Check and reposition right and left engine support assemblies as required. Adjust drive train position, if required, for the following conditions:

• Drive shaft distress: See Group 2, Suspension

and Driveshaft.

• Any front end structural damage (after repair).

• Support Assembly replacement.

ENGINE SUPPORT ADJUSTMENT

(1) Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack.

(2) Loosen the right engine support assembly vertical fasteners.

(3) Loosen the left engine support assembly vertical bolts.

(4) Pry the engine right or left as required to achieve the proper drive shaft assembly length. Refer to Group 2, Suspension and Driveshaft for driveshaft identification and related assembly length measuring.

(5) Tighten right engine support assembly vertical bolts to 61 N·m (45 ft. lbs.). and tighten left engine support assembly bolts to 61 N·m (45 ft. lbs.).

(6) Recheck drive shaft length.

Fig. 109 Cylinder Bore and Piston Specifications

9 - 50 2.0L SOHC ENGINE JA

SPECIFICATIONS

ENGINE 2.0L SOHC

Cylinder Block

Cylinder Bore Diameter . . . 87.4924 - 87.5076 mm

(3.4446 - 3.4452.in.)

Out-of-Round (Max.) .......0.051 mm (0.002 in.)

Taper (Max.) .............0.051 mm (0.002 in.)

Pistons

Clearance 17.5 mm (11/16 in.)

from bottom of skirt ........0.012 - 0.044 mm

(0.0004 - 0.0017 in.)

Weight .....................325-335grams

(11.47 - 11.82 oz.)

Land Clearance (Diametrical) . . 0.734 - 0.797 mm

(0.029 - 0.031 in.)

Piston Length ..............64mm(2.520 in.)

Piston Ring Groove Depth

No.1 .....3.989 - 4.188 mm (0.157 - 0.165 in.)

Piston Ring Groove Depth

No.2 .....4.462 - 4.661 mm (0.176 - 0.184 in.)

Piston Ring Groove Depth

No.3 .....3.847 - 4.131 mm (0.151 - 0.163 in.)

Piston Pins

Clearance in Piston ..........0.008 - 0.020 mm

(0.0003 - 0.0008 in.)

In Rod (Interference) .........0.018 - 0.043 mm

(0.0007 - 0.0017 in.)

Diameter ................20.998 - 21.003 mm

(0.8267 - 0.8269 in.)

End Play ............................None

Length .....74.75 - 75.25 mm (2.943 - 2.963 in.)

Piston Rings

Ring Gap Top Compression

Ring .....................0.23 - 0.52 mm

(0.009 - 0.020 in.) Ring Gap 2nd Compression

Ring .....................0.49 - 0.78 mm

(0.019 - 0.031 in.)

Ring Gap Oil Control

(Steel Rails) ................0.23 - 0.66 mm

(0.009 - 0.026 in.)

Ring Side Clearance Both

Compression Rings ..........0.025 - 0.065 mm

(0.0010 - 0.0026 in.)

Oil Ring (Pack) .............0.004 - 0.178 mm

(0.0002 - 0.0070 in.)

Ring Width Compression

Rings .....................1.17 - 1.19 mm

(0.046 - 0.047 in.)

Oil Ring (Pack) .............2.854 - 3.008 mm

(0.1124 - 0.1184 in.)

Connecting Rod

Bearing Clearance ...........0.026 - 0.059 mm

(0.001 - 0.0023 in.)

Piston Pin Bore Diameter .....20.96 - 20.98 mm

(0.8252 - 0.8260 in.)

Large End Bore Diameter . . . 50.991 - 51.005 mm

(2.0075 - 2.0081 in.)

Side Clearance ...............0.13 - 0.38 mm

(0.005 - 0.015 in.)

Total Weight (Less Bearing) .........543grams

(1.20 lbs.)

Crankshaft

Connecting Rod

Journal Diameter ......47.9924 - 48.0076 mm

(1.8894 - 1.8900 in.)

Out-of-Round (Max.) .....0.0035 mm (0.0001 in.)

Taper (Max.) ...........0.0038 mm (0.0001 in.)

Main Bearing Diametrical

Clearance No.1-5 ........0.022 - 0.062 mm

(0.0008 - 0.0024 in.)

End Play ....0.09 - 0.24 mm (0.0035 - 0.0094 in.)

Main Bearing Journals

Diameter ..............51.9924 - 52.0076 mm

(2.0469 - 2.0475 in.)

Out-of-Round (Max.) .....0.0035 mm (0.0001 in.)

Taper (Max.) ...........0.0038 mm (0.0001 in.)

JA 2.0L SOHC ENGINE 9 - 51

SPECIFICATIONS (Continued)

ENGINE 2.0L SOHC

Rocker Arm Shaft

Diameter ..............19.996 – 19.984mm

(0.786 – 0.7867 in.)

Rocker Arm Shaft Retainers (Width)

Intake (All) ...............28.46 mm (1.12 in.)

Exhaust .............1&529.20 mm (1.14in.)

2, 3, and 4 - 40.45 mm (1.59 in.)

Rocker Arm/Hydraulic Lash Adjuster *

Rocker Arm Inside Diameter . . 20.00 – 20.02 mm

(0.787 – 0.788 in.)

Rocker Arm Shaft Clearance . . . 0.016 – 0.054 mm

(0.0006 – 0.0021 in.)

Body Diameter ...........22.949 – 22.962 mm

(0.9035 – 0.9040 in.)

Plunger Travel

Minimum (Dry) ..........2.2mm(0.087 in.)

Rocker Arm Ratio ...................1.4to1

Camshaft

No.1 ....41.20 – 41.221 mm (1.622 – 1.6228 in.)

No.2 ......41.6 – 41.621 mm (1.637 – 1.638 in.)

No.3 ......42.0 – 42.021 mm (1.653 – 1.654 in.)

No.4 ......42.4 – 42.421 mm (1.669 – 1.670 in.)

No.5 .....42.8 – 42.821 mm (1.685 – 1.6858 in.)

Bearing Journal Diameter

No. 1 . . . 41.128 – 41.147 mm (1.619 – 1.6199 in.)

No.2 ....41.528 – 41.547 mm (1.634 – 1.635 in.)

No.3 ....41.928 – 41.947 mm (1.650 – 1.651 in.)

No.4 ....42.328 – 42.374 mm (1.666 – 1.668 in.)

No. 5 . . . 42.728 – 42.747 mm (1.682 – 1.6829 in.)

Diametrical Bearing

Clearance ...............0.053 – 0.093 mm

(0.0027 – 0.003 in.)

Max. Allowable ...........0.12 mm (0.0047 in.)

End Play ..........0.05 – 0.39 mm (0.0059 in.)

Lift (Zero Lash )

Intake ...................7.8mm(0.307 in.)

Exhaust .................7.03 mm (0.277 in.)

Valve Timing Exhaust Valve

Closes (ATDC) ........................5.4°

Opens (BBDC) .......................43.7°

Duration ...........................229.1°

Valve Timing Intake Valve **

Closes (ABDC) .......................41.1°

Opens (ATDC) ........................13.9°

Duration ...........................207.2°

Valve Overlap ..........................0°

Cylinder Head

Material ....................Cast Aluminum

Gasket Thickness

(Compressed) ...........1.15 mm (0.045 in.)

Valve Seat

Angle ................................45°

Runout (Max.) ..............0.050 mm (0.002)

Width (Finish) Intake

and Exhaust ...............0.75 – 1.25 mm

(0.030 – 0.049 in.)

Valve Guide Finished

Diameter I.D. ..............5.975 – 6.000 mm

(.235 – .236 in.)

Guide Bore Diameter (Std.) .....11.0–11.02 mm

(0.4330 – 0.4338 in.)

Valves

Face Angle Intake and Exhaust .....45–45-1/2°

Head Diameter Intake .......32.12 – 33.37 mm

(1.303 – 1.313 in.)

Head Diameter Exhaust ......28.57 – 28.83 mm

(1.124 – 1.135 in.)

Valve Margin

Intake ......................1.15 – 1.48 mm

(0.0452 – 0.0582 in.)

Exhaust ..................1.475 – 1.805 mm

(0.058 – 0.071 in.)

Valve Length (Overall)

Intake ..................114.69 – 115.19 mm

(4.515 – 4.535 in.)

Exhaust .................109.59 – 110.09 mm

(4.603 – 4.623 in.)

Valve Stem Tip Height

Intake ....................45.01 – 46.07 mm

(1.77 – 1.81 in.)

Exhaust ..................43.51 – 44.57 mm

(1.71 – 1.75 in.)

Stem Diameter

Intake ....................5.934 – 5.952 mm

(0.234 – 0.234 in.)

Exhaust ..................5.906 – 5.924 mm

(0.233 – 0.233 in.)

Stem to Guide Clearance

Intake ....................0.048 – 0.066 mm

(0.0018 – 0.0025 in.)

Exhaust .................0.0736 – 0.094 mm

(0.0029 – 0.0037 in.)

Max. Allowable Intake .....0.076 mm (0.003 in.)

Max. Allowable Exhaust ....0.101 mm (0.004 in.)

Valve Springs

Free Length (Approx.) ......44.4 mm (1.747 in.)

Nominal Force

(Valve closed) ...........91N·m@39.8 mm

(67 ft. lbs. @ 1.57 in.)

Nominal Force

(Valve open) ...........239N·m@32.6 mm

(176 lbs. @ 1.28 in.)

Installed Height ..........40.18 mm (1.580 in.)

* SERVICE AS AN ASSEMBLY WITH ROCKER

ARM.

** ALL READINGS IN CRANKSHAFT DEGREES,

AT 0.5 mm (0.019 in.) OF VALVE LIFT.

9 - 52 2.0L SOHC ENGINE JA

SPECIFICATIONS (Continued)

TORQUE CHART 2.0L SOHC

DESCRIPTION ...................TORQUE

Camshaft Sensor Pick Up

Bolts ...................9.6N·m(85in.lbs.)

Timing Belt Cover

Bolts M6 ................12N·m(105 in. lbs.)

Camshaft Sprocket

Bolt ....................115N·m(85ft.lbs.)

Connecting Rod Cap

Bolts .........27N·m(20ft.lbs.) Plus 1/4 Turn

Crankshaft Main Bearing Cap/Bedplate

M8 Bedplate Bolts ..........30N·m(22ft.lbs.)

M11 Main Cap Bolts ........81N·m(60ft.lbs.)

Crankshaft Damper

Bolt ...................142N·m(105 ft. lbs.)

Cylinder Head

Bolts .......Refer To Cylinder Head Installation

Cylinder Head Cover

Bolts ...................12N·m(105 in. lbs.)

Engine Mount Bracket

Bolts ....................41N·m(30ft.lbs.)

Exhaust Manifold to Cylinder Head

Bolts ...................23N·m(200 in. lbs.)

Exhaust Manifold Heat Shield

Bolts ...................12N·m(105 in. lbs.)

Front Torque Bracket—2.0/2.4L Engine

Bolts ....................33N·m(24ft.lbs.)

Front Torque Bracket Strut—2.0/2.4L Engine

Long Bolts ...............110N·m(80ft.lbs.)

Short Bolt ................61N·m(45ft.lbs.)

Intake Manifold

Bolts ...................12N·m(105 in. lbs.)

Oil Filter Adapter

Fastener .................80N·m(60ft.lbs.)

Oil Filter .................20N·m(15ft.lbs.)

Oil Pan

Bolts ...................12N·m(105 in. lbs.)

Drain Plug ...............27N·m(20ft.lbs.)

Oil Pump Attaching

Bolts ...................28N·m(250 in. lbs.)

Oil Pump Cover Fastener . . . 12 N·m (105 in. lbs.) Oil Pump Pick-up

Tube Bolt .............28N·m(250 in. lbs.)

Oil Pump Relief Valve Cap . . . 41 N·m (30 ft. lbs.)

Rear Torque Bracket

Bolts ...................110N·m(80ft.lbs.)

Rocker Arm Shaft

Bolts ...................28N·m(250 in. lbs.)

Spark Plugs ...............28N·m(20ft.lbs.)

Support Module—Front and Rear

Thru Bolt ................61N·m(45ft.lbs.)

Thermostat Housing

Bolts ...................23N·m(200 in lbs.)

Timing Belt

Tensioner ...............31N·m(275 in. lbs.)

Timing Belt Tensioner Pivot Bracket

Bolt ....................31N·m(275 in. lbs.)

Timing Belt Tensioner Pulley

Bolt .....................68N·m(50ft.lbs.)

Water Pump Mounting

Bolts ...................12N·m(105 in. lbs.)

JA 2.0L SOHC ENGINE 9 - 53

SPECIAL TOOLS

ENGINE 2.0L SOHC

Camshaft Sprocket Remover/InstallerAdapter

C-4687-1

Puller 1026

Crankshaft Damper Removal Insert6827-A

Camshaft Sprocket Remover/InstallerC-4687

Camshaft Seal Remover C-4679-A

Camshaft Seal Installer MD-998306

Crankshaft Damper Installer 6792

9 - 54 2.0L SOHC ENGINE JA

SPECIAL TOOLS (Continued)

Crankshaft Damper Installer C-4685-C

Valve Spring Compressor MD-998772-A

Spring Compressor Adapter 6779

Cylinder Bore Indicator C-119

Front Crankshaft Seal Remover 6771

Front Crankshaft Seal Installer 6780

Valve Spring Compressor C-3575-A

Crankshaft Sprocket Remover 6793

JA 2.0L SOHC ENGINE 9 - 55

SPECIAL TOOLS (Continued)

Crankshaft Sprocket Installer 6792

Rear Crankshaft Seal Guide and Installer6926-1 and

6926-2

Pressure Gage C-32932

Valve Spring Tester C-647

9 - 56 2.4L ENGINE JA

2.4L ENGINE

INDEX

page page

DESCRIPTION AND OPERATION

ENGINE COMPONENTS ................. 57

ENGINE LUBRICATION SYSTEM ........... 58

ENGINE .............................. 57

GENERAL SPECIFICATIONS .............. 57

DIAGNOSIS AND TESTING

CHECKING ENGINE OIL PRESSURE ........ 59

SERVICE PROCEDURES

CAMSHAFT END PLAY .................. 63

CRANKSHAFT END PLAY ................ 63

CYLINDER BORE AND SIZING PISTON ...... 59

FITTING CONNECTING ROD BEARINGS ..... 61

FITTING MAIN BEARINGS ................ 61

FITTING PISTON RINGS ................. 60

REMOVAL AND INSTALLATION

BALANCE SHAFTS CARRIER ASSEMBLY .... 70

CAMSHAFT FOLLOWER ................. 69

CAMSHAFT ........................... 68

CRANKSHAFT ......................... 82

CYLINDER HEAD COVER ................ 68

CYLINDER HEAD ....................... 73

ENGINE ASSEMBLY ..................... 65

ENGINE MOUNT—RIGHT/ENGINE SUPPORT

BRACKET ........................... 65

ENGINE SUPPORT MODULE (FRONT AND

REAR MOUNTS) ...................... 64

FRONT CAMSHAFT OIL SEAL ............. 79

FRONT CRANKSHAFT OIL SEAL ........... 80

HYDRAULIC LASH ADJUSTER ............ 73

LEFT SIDE MOUNT ..................... 64

OILFILTER ........................... 84

OILPAN .............................. 78

OIL PUMP ............................ 84

PISTON AND CONNECTING ROD .......... 85

REAR CRANKSHAFT SEAL ............... 81

TIMING BELT COVER ................... 76

TIMING BELT TENSIONER ................ 78

TIMING BELT .......................... 77

VALVE SPRINGS AND VALVE SEALS IN

VEHICLE ............................ 73

VALVES AND VALVE SPRINGS ............ 75

VIBRATION DAMPER .................... 75

DISASSEMBLY AND ASSEMBLY

OIL PUMP ............................ 87

CLEANING AND INSPECTION

OIL PUMP ............................ 88

CAMSHAFT FOLLOWER ................. 91

CRANKSHAFT ......................... 90

CYLINDER BLOCK ...................... 90

CYLINDER HEAD ....................... 88

VALVE AND VALVE SPRING .............. 88

ADJUSTMENTS

ENGINE SUPPORT ADJUSTMENT .......... 91

SPECIFICATIONS

ENGINE 2.4L .......................... 92

TORQUE CHART 2.4L ................... 94

SPECIAL TOOLS

ENGINE 2.4L .......................... 95

ENGINE IDENTIFICATIONLOCATION

JA 2.4L ENGINE 9 - 57

DESCRIPTION AND OPERATION

ENGINE

ENGINE IDENTIFICATION

The engine identification number is located on the

rear of the cylinder block (Fig. 1).

Fig. 1 Engine Identification

Engine—2.4L

GENERAL SPECIFICATIONS

Type.....................In-Line OHV, DOHC

Bore ....................87.5 mm (3.444 Inch)

Stroke ..................101mm(3.976 Inches)

Compression Ratio ......................9.4:1

Displacement .......2.4Liters (148 Cubic Inches)

Firing Order ........................1,3,4,2

Compression Pressure ...........1069 - 1172 kPa

(170 - 225 psi)

Maximum Variation Between Cylinders ......25%

Lubrication; Pressure Feed-Full Flow

Filtration (Direct Crankshaft Driven Pump Engine

Oil Capacity .............Including Oil Filter

4.25 Liter (4.5 Qts.) Without Oil Filter

3.8 Liter (4.0 Qts.)

ENGINE COMPONENTS

BALANCE SHAFTS: 2.4L engines are equipped with two balance shafts installed in a carrier attached to the lower crankcase. The shafts interconnect through gears to rotate in opposite directions. These gears are driven by a short chain from the crankshaft, to rotate at two times crankshaft speed. This counterbalances certain engine reciprocating masses.

9 - 58 2.4L ENGINE JA

DESCRIPTION AND OPERATION (Continued)

CYLINDER BLOCK AND BEDPLATE ASSEM-

BLY: A closed deck design is used for cooling and

weight reduction with water pump molded into the block. Nominal wall thickness is 4.5 mm. The bedplate incorporates main bearing caps. Rear seal retainer is integral with the block.

CRANKSHAFT: A nodular cast iron crankshaft is used. The engine has 5 main bearings, with number 3 flanged to control thrust. The 60 mm diameter main and 50 mm diameter crank pin journals (all) have undercut fillets that are deep rolled for added strength. To evenly distribute bearing loads and minimize internal stress, 8 counterweights are used. Hydrodynamic seals provide end sealing, where the crankshaft exits the block. Anaerobic gasket material is used for parting line sealing in the block. A sintered powder metal timing belt sprocket is mounted on the crankshaft nose. This sprocket provides motive power; via timing belt to the camshaft sprockets (providing timed valve actuation) and to the water pump.

PISTONS: There is provisions for free wheeling valve train. Piston has a unique height. All engines use pressed in piston pins to attach forged powder metal connecting rods. Incorporate hex head cap screw threaded into the connecting rod. Piston and Rods are serviced as a assembly.

PISTONS RINGS: The piston rings include a molybdenum faced top ring for reliable compression sealing and a chrome plated taper faced intermediate ring for additional cylinder pressure control. There are also standard oil control rings.

CYLINDER HEAD: Features a Dual Over Head Camshaft (DOHC) 4 valves per cylinder cross flow design. The valves are arranged in two inline banks, with the ports of the bank of two intake valves per cylinder facing toward the radiator side of engine and ports of the bank of two exhaust valves per cylinder facing toward the dash panel. Incorporates powder metal valve guides and seats. Integral oil galleys within the cylinder head supplies oil to the hydraulic lash adjusters, camshaft and valve mechanisms.

CAMSHAFTS: The nodular iron camshafts have six bearing journals and 2 cam lobes per cylinder. Flanges at the rear journals control camshaft end play. Provision for cam position sensor is located on the intake camshaft at the rear of cylinder head. A hydrodynamic oil seal is used for oil control at the front of the camshaft.

VALVES: 4 valves per cylinder are actuated by roller cam followers which pivot on stationary hydraulic lash adjusters. All valves have 6 mm diameter chrome plated valve stems. The valve sizes are

34.8 mm (1.370 inch.) diameter intake valves and

30.5 mm (1.20 inch.) diameter exhaust valves. Viton

rubber valve stem seals are integral with the spring seats. Valve springs, spring retainers, and locks are conventional.

INTAKE MANIFOLD: The intake manifold is a one piece aluminum casting, attached to the cylinder head with ten screws. This long branch fan design enhances low and midspeed torque.

EXHAUST MANIFOLD: The exhaust manifold is made of cast iron for strength and high temperatures.

ENGINE LUBRICATION: Refer to Group 0 Lubrication and Maintenance for recommended oil 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, supplying main and rod bearings with further routing. Pistons are lubricated from rod bearing throw off and lubricating slots on 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.

ENGINE LUBRICATION SYSTEM

OIL PAN

A structural die cast aluminum oil pan provides lower engine protection as well as serving as the engine oil reservoir. Oil pan is attached to block and sealed with a gasket. The oil pickup tube has a strainer and cover.

PRESSURE LUBRICATION

Oil drawn up through the pickup tube is pressurized by the pump and routed through the full flow filter to the main oil gallery running the length of the cylinder block. Oil pickup, pump and check valve provide oil flow to the main oil gallery.

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 past a cylinder head bolt to an oil gallery running the length of the cylinder head. The camshaft journals are partially slotted to allow a predetermined amount of pressurized oil to pass into the bearing cap cavities with small holes directed to spray lubricate the camshaft lobes.

FRONT USE FORSIZINGPISTON

MIDDLE

OF BORE

10 mm(3/8 IN.)10 mm(3/8 IN.)

PISTON O.D. MEASURE-MENT LOCATION

JA 2.4L ENGINE 9 - 59

DESCRIPTION AND OPERATION (Continued)

BALANCE SHAFTS

Balance shaft lubrication is provided through an oil passage from the number 1 main bearing cap through the balance shaft carrier support leg. This passage directly supplies oil to the front bearings and internal machined passages in the shafts that routes oil from front to rear shaft bearing journals

SPLASH LUBRICATION

DIAGNOSIS AND TESTING

CHECKING ENGINE OIL PRESSURE

(1) Remove oil pressure sending unit and install gauge assembly C-3292.

(2) Run engine until thermostat opens.

CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM

(3) Oil Pressure: Curb Idle 25 kPa (4 psi) minimum 3000 RPM 170/550 kPa (25/80 psi).

(4) If oil pressure is 0 at idle. Shut off engine, check for pressure relief valve stuck open or a clogged oil pickup screen.

SERVICE PROCEDURES

CYLINDER BORE AND SIZING PISTON

Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin about 14 mm (9/16 inch.) from the bottom 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. 2). Refer to (Fig. 3) for specifications. Correct piston to bore clearance must be established in order to assure quiet and economical operation.

Chrysler engines use pistons designed specifically for each engine model. Clearance and sizing locations vary with respect to engine model.

Fig. 2 Checking Cylinder Bore Size

Standard Bore

87.5 mm (3.445 in.)

Maximum Out-

of-Round

0.051 mm (0.002 in.)

Maximum

Taper

0.051 mm (0.002 in.)

Standard Piston Size

87.450 - 87.468 mm (3.4434 - 3.4441 in.) Piston to Bore Clearance: 0.024 - 0.057 mm (,0009 to

.0022 in.) Measurements taken at Piston Size location

Fig. 3 Cylinder Bore and Piston Specifications

NOTE: Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C).

Fig. 4 Piston Measurement

FEELER GAUGE

NO. 1 PISTON RINGNO. 2 PISTON RING SIDE RAILOIL RINGSPACEREXPANDER

FEELER GAUGE

9 - 60 2.4L ENGINE JA

SERVICE PROCEDURES (Continued)

FITTING PISTON RINGS

(2) Check piston ring to groove side clearance (Fig.

6). Refer to specification in piston ring specifications table.

Fig. 6 Piston Ring Side Clearance

PISTON RINGS—INSTALLATION

Fig. 5 Piston Ring Gap

PISTON RING SPECIFICATIONS

Ring Position Ring Gap Wear Limit

Upper Ring 0.025 to 0.51

mm (0.0098 to

Intermediate Ring

0.020 in.)

0.23 to 0.48 mm (0.009 to

0.8 mm (0.031 in.)

0.018 in.)

Oil Control Ring 0.25 to 0.64

mm (0.0098 to

1.0 mm (0.039 in.)

0.025 in.)

Ring Position Groove

Max. Clearance

Clearance

Upper Ring 0.030 to 0.080

mm (0.0011 to

0.10 mm (0.004 in.)

0.0031 in.)

Intermediate Ring

0.025 to 0.065 mm (0.0010 to

0.10 mm (0.004 in.)

0.0026 in.)

Oil Control Ring - Three Piece. Oil Ring Side Rails Must Be Free To Rotate After Assembly.

Fig. 7 Piston Ring Installation

(1) Install rings with manufacturers I.D. mark fac-

ing up, to the top of the piston (Fig. 7).

CAUTION: Install piston rings in the following order:

a. Oil ring expander. b. Upper oil ring side rail. c. Lower oil ring side rail. d. No. 2 Intermediate piston ring. e. No. 1 Upper piston ring.

(2) 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. 8).

GAP OF LOWERSIDE RAIL NO. 1 RING GAPGAP OF UPPERSIDE RAILNO. 2 RING GAP ANDSPACER EXPANDERGAP FRONT OF ENGINE

SIDE RAIL END

JA 2.4L ENGINE 9 - 61

SERVICE PROCEDURES (Continued)

(3) Install upper side rail first and then the lower

side rail.

(4) Install No. 2 piston ring and then No. 1 piston

ring.

Fig. 8 Installing Side Rail

(5) Position piston ring end gaps as shown in (Fig.

9). (6) 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 important for oil control.

imately 6.35 mm (1/4 in.) off center and away from the oil hole (Fig. 10). In addition, suspect areas can be checked by placing plastigage in the suspect area.

Fig. 10 Measuring Plastigage Width

(4) Before assembling the rod cap with Plastigage in place, the crankshaft must be rotated until the connecting rod being checked starts moving toward the top of the engine. Only then should the cap be assembled and torqued to specifications. Do not

rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results.

(5) Remove the bearing cap and compare the width of the flattened Plastigage (Fig. 10) with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences 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.

(6) Plastigage is available in a variety of clearance ranges. The 0.025-0.076 mm (.001-.003 in.) is usually the most appropriate for checking engine bearing proper specifications.

Fig. 9 Piston Ring End Gap Position

FITTING CONNECTING ROD BEARINGS

Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent. The 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 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-

FITTING MAIN BEARINGS

Refer to the Engine General Information Section for Measuring Main Bearings. For Crankshaft specifications refer to Crankshaft Specification Table.

CRANKSHAFT MAIN BEARINGS

The crankshaft is supported in five main bearings. All upper and lower bearing shells in the crankcase have oil grooves. The number three lower main thrust bearing is plain. Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal (Fig. 11).

Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves

OIL GROOVES UPPER BEAR-INGSLOWER BEARINGS OIL HOLESFRONT

LUBRICATION GROOVESOIL HOLES

9 - 62 2.4L ENGINE JA

SERVICE PROCEDURES (Continued)

CRANKSHAFT SPECIFICATION TABLE

Crankshaft End-Play

New Part: 0.09 - 0.24 mm (0.0035 - 0.0094 in.) Wear Limit: 0.37 mm (0.015 in.)

Main Bearing Clearance

New Part: 0.018 - 0.058 mm (0.0007 - 0.0023 in.)

Connecting Rod Bearing Clearance

New Part: 0.025 - 0.071 mm (0.001 - 0.003 in.) Wear Limit: 0.075 mm (0.003 in.)

Crankshaft Journal Sizes

Main Bearing Journal Diameter Standard 60.000 6 0.008 mm (2.3622 6 0.0003 in.) 1 st Undersize 59.975 6 0.008 mm (2.361 6 0.0003 in.)

Connecting Rod Journals

Standard 49.992 6 0.008 mm (1.968 6 0.0003 in.) 1 st Undersize 49.967 6 0.008 mm (1.967 6 0.0003 in.)

in the engine (Fig. 11). 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: 0.025 mm (0.001 in.), 0.050 mm (0.002 in.), 0.250 mm (0.010 inch.) 0.275 mm (0.011 inch.) 0.300 mm (0.012 inch.). Never install an undersize bearing that will reduce clearance below specifications.

Fig. 12 Installing Main Bearing Upper Shell

CAUTION: Do not get oil on the bedplate mating surface. It will may effect the sealer ability to seal the bedplate to cylinder block.

(3) Oil the bearings and journals and install crankshaft.

CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine. Ensure that both cylinder block and bedplate surfaces are clean.

(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of anaerobic sealer Mopar Torque Cure Gasket Maker to cylinder block as shown in (Fig. 13).

Fig. 11 Main Bearing Identification

MAIN BEARING INSTALLATION

(1) Install the main bearing shells with the lubri-

cation groove in the cylinder block (Fig. 12).

(2) Make certain oil holes in block line up with oil holes in bearings. Bearing tabs must seat in the block tab slots.

Fig. 13 Main Bearing Caps/Bedplate Sealing

(5) Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. Install the main bearing/bedplate into engine block.

(6) Before installing the bolts the threads should be oiled with clean engine oil, wipe off any excess oil.

FRONTOFENGINE

JA 2.4L ENGINE 9 - 63

SERVICE PROCEDURES (Continued)

(3) Zero the dial indicator.

(4) Move crankshaft all the way to the front and read the dial indicator. Refer to Crankshaft Specification Table for end-play specification.

CRANKSHAFT SPECIFICATION TABLE

Crankshaft End-Play

New Part: 0.09 - 0.24mm (0.0035 - 0.0094 in.) Wear Limit: 0.37 mm (0.015 in.)

OPTIONAL CRANKSHAFT END PLAY CHECK

(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-

Fig. 14 Main Bearing Caps/Bedplate

TorqueSequence

(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 cylinder block. Then torque these bolts to 28 N·m (20 ft. lbs.).

(8) Install main bearing bedplate to engine block bolts (1 through 10) and torque each bolt to 41 N·m (30 ft. lbs.) in sequence then in sequence turn each bolt 1/4 turn shown in (Fig. 14).

(9) Install main bearing bedplate to engine block bolts (11 through 20), and torque each bolt to 28 N·m (20 ft. lbs.) in sequence shown in (Fig. 14).

(10) After the main bearing bedplate is installed, check the crankshaft turning torque. The turning

torque should not exceed 5.6 N·m (50 in. lbs.).

age any bearing surface. DO NOT loosen main bearing cap.

(2) Use a feeler gauge between number three thrust bearing and machined crankshaft surface to determine end play.

CAMSHAFT END PLAY

(1) Oil camshaft journals and install camshaft WITHOUT cam follower assemblies. Install rear cam caps and tighten screws to specified torque.

(2) Using a suitable tool, move camshaft as far rearward as it will go.

(3) Zero dial indicator (Fig. 16).

(4) Move camshaft as far forward as it will go.

(5) End play travel: 0.05 - 0.15 mm (0.002 - 0.010 in.).

(6) If end play is excessive check cylinder head and camshaft for wear; replace as necessary.

CRANKSHAFT END PLAY

Fig. 15 Checking Crankshaft End Play—Typical

(1) Mount a dial indicator to front of engine, locat-

ing probe on nose of crankshaft (Fig. 15).

(2) Move crankshaft all the way to the rear of its

travel.

Fig. 16 Camshaft End Play

LOWER RADIATOR SUP-PORTFRONT ENGINEMOUNTDAMPER WEIGHT (SOMEMODELS)ENGINE SUPPORT MODULEREAR ENGINEMOUNTREAR STRUT BRACKETSUPPORT BRACKET (SOMEMODELS)

FWD EXHAUST MANI-FOLDSTRUTPOWER STEERINGPUMPFWDSTRUT P/S BRACKETENGINE SUPPORTMODULEREAR MOUNTREAR TORQUE BRACKET

TORQUEREAR TORQUE BRACKETENGINESTARTER WIRINGCLIP (2.5LENGINE)STRUTTRANSMISSIONSUPPORT 61 N·m (45 ft. lbs.)110 N·m (80 ft. lbs.)

9 - 64 2.4L ENGINE JA

REMOVAL AND INSTALLATION

ENGINE SUPPORT MODULE (FRONT AND REAR MOUNTS)

REMOVAL

(1) Raise vehicle on hoist. (2) Remove thru bolt at rear mount and remove

bolts attaching module to crossmember.

(3) Remove upper attaching bolt from rear support

strut bracket (Fig. 16).

(4) Remove front attaching bolts from support

module to lower radiator support.

(5) Support cooling module. (6) Remove lower radiator support bolts, and

remove support.

(7) Remove thru bolt at front mount and remove

support module.

Fig. 18 Engine Mounting—Rear 2.4 and2.5L

Fig. 17 Engine Support Module

INSTALLATION

(1) Install thru bolt at front mount. Do not tighten

at this time.

(2) Install lower radiator support. (3) Install attaching bolts from support module to

lower radiator support.

(4) Install upper bolt at rear support strut bracket. (5) Install thru bolt at rear mount see (Fig. 17) or

(Fig. 18) tighten to 61 N·m (45 ft. lbs.).

(6) Tighten thru bolt at front mount see (Fig. 19)

tighten to 61 N·m (45 ft. lbs.).

LEFT SIDE MOUNT

NOTE: If centering or adjusting the engine/transmission assembly is needed refer to Adjustments, in this section.

The left side engine mount is a Hydro-Mount and may show surface cracks this will not effect it’s performance and should not be replaced. Only replace the Hydro-Mount when it’s leaking fluid.

Fig. 19 Engine Mounting—Rear 2.0L

(1) Support the transmission with a transmission

jack.

(2) Remove the three vertical bolts, from the

mount to the transmission.

ENGINE FWD FRONT TORQUEBRACKETFRONTMOUNTSTRUT (SOME MODELS)A/C COMPRESSORFWDSTRUT ENGINE SUPPORT MOD-ULE

TRANSMISSION TORQUETRANSMISSIONBRACKET LEFT FRAMERAILGROUND CABLETRANSMISSION SUPPORTASSEMBLYFWD 61 N·m (45 ft. lbs.)

33 N·m (24 ft. lbs.)

RIGHT ENGINE SUPPORTASSEMBLYFRAMERAIL 45 FT. LBS. (61 N·m) FWD

JA 2.4L ENGINE 9 - 65

REMOVAL AND INSTALLATION (Continued)

ENGINE MOUNT—RIGHT/ENGINE SUPPORT BRACKET

(1) Raise vehicle on a hoist and remove inner splash shield. Remove the right engine support assembly vertical fasteners from frame rail (Fig. 14).

(2) Lower vehicle. Remove the load on the engine motor mounts by carefully supporting the engine assembly with a floor jack.

(3) Remove the three bolts attaching the engine support assembly to the engine bracket.

(4) Move the air conditioning dryer aside.

(5) Remove coolant recovery system tank. Refer to Group 7, Cooling System for procedure.

(6) Remove right engine support.

(7) Remove the three bolts attaching the engine support bracket to the cylinder block.

Fig. 20 Engine Mounting—Front 2.0 and2.4L

(3) Remove the transmission mount fasteners and

remove mount.

(4) Reverse removal procedure for installation.

Refer to (Fig. 21) for bolt tightening specifications.

(5) Engine support assemblies adjustment, Refer to Engine Support Assembly Adjustment of this section.

NOTE: If centering or adjusting the engine/transmission assembly is needed refer to Adjustments, in this section.

(8) Reverse removal procedure for installation.

Refer to (Fig. 14) for torque specifications.

Fig. 22 Engine Mounting—Right Side

ENGINE ASSEMBLY

Fig. 21 Typical Engine Mounting—Left

REMOVAL

(1) Perform fuel pressure release procedure. Refer to Group 14, Fuel System for procedure. Remove fuel line to fuel rail.

(2) Disconnect battery and remove air cleaner and hoses.

9 - 66 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

(3) Drain cooling system. Refer to Draining Cool-

ing System in Group 7.

(4) Discharge Air Conditioning System. (5) Disconnect automatic transmission cooler lines

and plug, if equipped.

(6) Remove cooling module assembly (radiator, fan

module, and condenser).

(7) Disconnect transmission shift linkage. (8) Disconnect throttle body linkage. (9) Disconnect engine and transmission wiring

harness.

(10) Disconnect heater hoses. (11) Hoist vehicle and remove right inner splash

shield. Remove battery splash shield.

(12) Drain engine oil. (13) Remove accessory drive belts. Refer to Acces-

sory Drive Belt Removal in Group 7.

(14) Remove axle shafts. (15) Disconnect exhaust pipe from manifold. (16) Remove engine support module. (17) Remove front and rear mount brackets from

the engine and transmission.

(18) Remove rear engine/transmission bending brace. Remove flex plate cover. Remove converter bolts and mark converter for reassembly.

(19) Lower vehicle.

(20) Remove power steering pump, reservoir and hoses. Position components for engine removal.

(21) Remove A/C suction line at compressor. Cap suction port and line.

(22) Remove ground straps to body.

(23) Raise vehicle enough to allow engine dolly

6135 and cradle 6710 with posts 6848 to be installed under vehicle (Fig. 23).

(24) Loosen cradle engine mounts to allow movement for positioning onto engine locating holes on the engine bedplate, compressor and support bracket. Install adapters 6909 to the two post at rear of engine Lower vehicle and position cradle mounts until the engine is resting on mounts. Tighten mounts to cradle frame. This will keep mounts from moving when removing or installing engine and transmission.

(25) Lower vehicle so weight of the engine and transmission ONLY is on the cradle.

(26) Remove engine and transmission mount bolts.

(27) Raise vehicle slowly. It may be necessary to move the engine/transmission assembly on the cradle to allow for removal around body flanges.

INSTALLATION

(1) Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine and transmission.

(2) Align engine and transmission mounts to attaching points. Install mounting bolts at the right engine and left transmission mounts. Refer to procedures outlined in this section.

(3) Slowly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135 and 6710.

(4) Install axle shafts.

(5) Install front and rear mount brackets.

(6) Install transmission and engine bending brace.

(7) Install engine support module.

(8) Connect exhaust system to manifold.

(9) Install power steering pump, reservoir and hoses.

(10) Install A/C suction line at compressor.

(11) Install accessory drive belts. Refer to Accessory Drive Belt Installation in Group 7.

(12) Install right inner splash shield and battery splash shield. Install wheels and tires.

(13) Install cooling module assembly (radiator, fan module, and condenser).

(14) Connect automatic transmission cooler lines and shifter linkage.

(15) Connect fuel line and heater hoses.

(16) Install ground straps. Connect engine and throttle body connections and harnesses.

(17) Connect throttle body linkage.

(18) Fill cooling system.

(19) Connect battery.

(20) Install air cleaner and hoses.

(21) Install oil filter. Fill engine crankcase with proper oil to correct level.

(22) Start engine and run until operating temperature is reached.

(23) Adjust transmission linkage, if necessary.

SPECIAL TOOLSPOST 6848FRONT VIEWSPECIAL TOOLS POST 6848WITH ADAPTERS 6909REAR VIEWSPECIAL TOOL 6135 DOLLYSPECIAL TOOL 6710 CRA-DLE

JA 2.4L ENGINE 9 - 67

REMOVAL AND INSTALLATION (Continued)

Fig. 23 Positioning Engine Cradle SupportPost Mounts

IGNITION COIL FASTENERSGROUND STRAP

ONE PIECE RUBBER GAS-KETSPARK PLUG WELL SEALS

FR0NT

9 - 68 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

CYLINDER HEAD COVER

REMOVAL

(1) Remove ignition coil pack and plug wires (Fig.

24). Remove ground strap. (2) Remove the cylinder head cover fasteners. (3) Remove cylinder head cover from cylinder

head.

Fig. 24 Ignition Coil Pack and Ground Strap

(a) Tighten all fasteners to 4.5 N·m (40 in. lbs.) (b) Tighten all fasteners to 9.0 N·m (80 in. lbs.) (c) Tighten all fasteners to 12 N·m (105 in. lbs.)

Fig. 26 Cylinder Head Cover Tightening Sequence

(4) Install ignition coil pack and plug wires.

Tighten fasteners to 12 N·m (105 in. lbs.).

(5) Install ground strap.

CAMSHAFT

REMOVAL

(1) Remove cylinder head cover using procedure

outlined in this section.

(2) Remove timing belt, sprockets and covers.

Refer to Timing Belt Service outlined in this section.

(3) Bearing caps are identified for location.

Remove the outside bearing caps first (Fig. 27).

(4) Loosen the camshaft bearing cap attaching fasteners in sequence shown (Fig. 28) one camshaft at a time.

CAUTION: Camshafts are not interchangeable. The intake cam number 6 thrust bearing face spacing is wider.

(5) Identify the camshafts before removing from the head. The camshafts are not interchangeable.

Fig. 25 Cylinder Head Cover Gasket and SparkPlug

Seals

INSTALLATION

NOTE: Replace spark plug well seals when installing a new cylinder head cover gasket.

(1) Install new cylinder head cover gaskets and

spark plug seals (Fig. 25).

CAUTION: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping.

(2) Apply Mopar Silicone Rubber Adhesive Sealant at the camshaft cap corners and at the top edge of the 1/2 round seal.

(3) Install cylinder head cover assembly to head and tighten fasteners in sequence shown in (Fig. 26). Using the 3 step torque method:

Fig. 27 Camshaft Bearing Cap Identification

REMOVE OUTSIDE BEARING CAPSFIRST

FRONT CAM CAP 1.5 mm (.060 in.) DIAMETERBEAD OF MOPAR GASKETMAKERLEFT REAR CAM CAP

JA 2.4L ENGINE 9 - 69

REMOVAL AND INSTALLATION (Continued)

to 12 N·m (105 in. lbs.) in sequence shown in (Fig.

30). (2) Apply Mopar Gasket Maker to No. 1 and No. 6

bearing caps (Fig. 31). Install bearing caps and tighten M8 fasteners to 28 N·m (250 in. lbs.).

(3) Bearing end caps must be installed before

seals can be installed.

(4) Install timing belt, sprockets and covers. Refer

to timing belt service outlined in this section.

(5) Install cylinder head cover using procedure

outlined in this section.

Fig. 28 Camshaft Bearing Cap— Removal

CAMSHAFT END PLAY

(1) Oil camshaft journals and install camshaft WITHOUT cam follower assemblies. Install rear cam caps and tighten screws to specified torque.

(2) Using a suitable tool, move camshaft as far rearward as it will go.

(3) Zero dial indicator (Fig. 29).

(4) Move camshaft as far forward as it will go.

(5) End play travel: 0.05–0.15 mm (0.002–0.010 in.).

(6) If end play is excessive check cylinder head and camshaft for wear; replace as necessary.

Fig. 30 Camshaft Bearing Cap Tightening Sequence

Fig. 29 Camshaft End Play

INSTALLATION

CAUTION: Ensure that NONE of the pistons are at top dead center when installing the camshafts.

(1) Remove camshaft retaining caps and lubricate bearing journals. Install cam followers and camshafts with clean oil. Install right and left camshaft bearing caps #2 thru #5 and right #6. Tighten M6 fasteners

Fig. 31 Camshaft Bearing Cap Sealing

CAMSHAFT FOLLOWER

REMOVAL

(1) Remove cylinder head cover using procedure

outlined in this section.

(2) Remove timing belt, sprockets and covers

using procedure outlined in this section.

(3) Remove camshaft. Refer to procedure previ-

ously outline this section.

(4) Remove cam follower assemblies from cylinder head. Keep the cam followers in the order they have been removed from the head for reassembly.

INSPECTION

TIP LASH ADJUSTERPOCKETROLLER

NICKEL PLATEDLINK AND MARK GEAR/SPROCKETSCREWSNICKEL PLATEDLINK AND DOT

STUD TENSIONER(ADJUSTER)GEAR COVERADJUSTSCREWPIVOT SCREWCHAIN COVER(CUTAWAY)GUIDE

9 - 70 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

Inspect the cam follower assembly for wear or

damage (Fig. 32). Replace as necessary.

Fig. 32 Cam Follower Assembly

INSTALLATION

(1) Lubricate with clean oil and install cam follower assemblies in their original position on the hydraulic adjuster and valve stem (Fig. 33).

(2) Install the camshafts. Refer to procedure previously outlined in this section.

(3) Install timing belt, sprockets and covers using procedure outlined in this section.

(4) Install cylinder head cover using procedure outlined in this section.

Fig. 34 Chain Cover, Guide and Tensioner

(1) Remove chain cover, guide and tensioner (Fig.

34). Also see Carrier Assembly Removal for service procedures requiring only temporary relocation of assembly.

Fig. 33 Cam Follower Assemblies—Installation

BALANCE SHAFTS CARRIER ASSEMBLY

BALANCE SHAFTS

REMOVAL

Refer to Timing Belt Cover, and Timing Belt removal procedure in this section. To repair balance shafts carrier assembly.

Fig. 35 Drive Chain and Sprockets

STUD (DOU-BLE ENDED) DRIVEGEAR DRIVENGEARCARRIERDOWELGEAR(S)GEARCOVER

REARCOVER CARRIERBALANCESHAFT

JA 2.4L ENGINE 9 - 71

REMOVAL AND INSTALLATION (Continued)

(2) Remove gear cover retaining stud (double ended to also retain chain guide). Remove cover and balance shaft gears (Fig. 34).

(3) Remove balance shaft gear and chain sprocket retaining screws and crankshaft chain sprocket. Remove chain and sprocket assembly (Fig. 35). Using two wide pry bars, work the sprocket back and forth until it is off the shaft.

Fig. 36 Gear Cover and Gears

BALANCE SHAFT CARRIER

REMOVAL

The following components will remain intact during carrier removal. Gear cover, gears, balance shafts and the rear cover (Fig. 37).

(1) Remove chain cover and driven balance shaft chain sprocket screw.

(2) Loosen tensioner pivot and adjusting screws, move driven balance shaft inboard through driven chain sprocket. Sprocket will hang in lower chain loop.

(3) Remove carrier to crankcase attaching bolts to remove carrier.

Balance Shaft Installation

Balance shaft and carrier assembly installation is the reverse of the removal procedure. During instal-

lation crankshaft to balance shaft timing must be established. Refer to Timing procedure outlined in this section.

TIMING

(1) With balance shafts installed in carrier (Fig.

38) position carrier on crankcase and install four attaching bolts and tighten to 54 N·m (40 ft. lbs.).

(2) Turn balance shafts until both shaft key ways are up Parallel to vertical centerline of engine. Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft. After installation gear and balance shaft keyways must be up with gear timing marks meshed as shown in (Fig.

39).

Fig. 37 Balance Shaft(s)—Removal/Installation

(4) Remove carrier gear cover and balance shafts

(Fig. 36).

(5) Remove four carrier to crankcase attaching

bolts to separate carrier from engine bedplate.

Fig. 38 Balance Shaft(s)—Removal/Installation

KEY WAYS UPGEAR ALIGNMENT DOTS

ALIGN FLAT ON SPROCKET WITHFLAT ON CRANKSHAFT WITHSPROCKET FACING FRONTSPECIAL TOOLNO. 6052DRIVESPROCKET

MARK ON SPROCKETBEDPLATEINSTALL CHAIN WITH ALLKEYWAYS UPLOWER NICKEL PLATEDLINK 8 LINK FROM UPPERLINKMUST LINE UP WITH NOTCHPARTING LINE NUMBERONE MAIN BEARINGNICKEL PLATED LINK

9 - 72 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

(8) With balance shaft keyways pointing up (12 o’clock) slide the balance shaft sprocket onto the nose of the balance shaft. The balance shaft may have to be pushed in slightly to allow for clearance.

Fig. 39 Gear Timing

Fig. 40 Crankshaft Sprocket—Installation

(3) Install gear cover and tighten double ended

stud/washer fastener to 12 N·m (105 in. lbs.).

(4) Install crankshaft sprocket using Special Tool

6052 (Fig. 40).

(5) Turn crankshaft until number one cylinder is at Top Dead Center (TDC). The timing marks on the chain sprocket should line up with the parting line on the left side of number one main bearing cap. (Fig. 41).

(6) Place chain over crankshaft sprocket so that the nickel plated link of the chain is over the number 1 cylinder timing mark on the crankshaft sprocket (Fig. 41).

(7) Place balance shaft sprocket into the timing chain (Fig. 41) so that the timing mark on the sprocket (yellow dot) mates with the (lower) nickel plated link on the chain

Fig. 41 Balance Shaft Timing

NOTE: THE TIMING MARK ON THE SPROCKET, THE (LOWER) NICKEL PLATED LINK, AND THE ARROW ON THE SIDE OF THE GEAR COVER SHOULD LINE UP WHEN THE BALANCE SHAFTS ARE TIMED CORRECTLY.

(9) If the sprockets are timed correctly install the balance shaft bolts and tighten to 28 N·m (250 in. lbs.). A wood block placed between crankcase and crankshaft counterbalance will prevent crankshaft and gear rotation.

CHAIN TENSIONING

(1) Install chain tensioner loosely assembled.

(2) Position guide on double ended stud making sure tab on the guide fits into slot on the gear cover. Install and tighten nut/washer assembly to 12 N·m (105 in. lbs.).

(3) Place a shim 1 mm (0.039 in.) thick x 70 mm (2.75 in.) long or between tensioner and chain. Push tensioner and shim up against the chain. Apply firm

pressure (5.5 to 6.6 lbs.) directly behind the

1MM (0.039 IN.)SHIMTENSIONER (ADJUSTER)BOLTPIVOTBOLT

VALVE SPRING COMPRES-SOR MD 998772AAIR HOSE

JA 2.4L ENGINE 9 - 73

REMOVAL AND INSTALLATION (Continued)

adjustment slot to take up all slack. Chain must have shoe radius contact as shown in (Fig. 42).

(4) With the load applied, tighten top tensioner bolt first, then bottom pivot bolt. Tighten bolts to 12 N·m (105 in. lbs.). Remove shim.

(5) Install carrier covers and tighten screws to 12 N·m (105 in. lbs.).

VALVE SPRINGS AND VALVE SEALS IN VEHICLE

REMOVAL

(1) Remove camshafts as previously outlined in

this section.

(2) Rotate crankshaft until piston is at TDC on

compression.

(3) With air hose attached to adapter tool installed in spark plug hole, apply 90-120 psi air pressure.

(4) Using Special Tool MD-998772-A with adapter 6779 (Fig. 43) compress valve springs and remove valve locks.

(5) Remove valve spring.

(6) Remove valve stem seal by a using valve stem seal tool.

Fig. 42 Chain Tension Adjustment

HYDRAULIC LASH ADJUSTER

REMOVAL

(1) Remove cylinder head cover. Refer to procedure

outlined in this section.

(2) Remove cam follower assembly. Refer to camshaft removal procedure outlined in this section to gain access to cam followers and lash adjusters.

(3) Mark hydraulic lash adjusters for reassembly in their original position. Lash adjusters are serviced as a assembly.

INSTALLATION

(1) Install hydraulic lash adjuster assembly making sure adjusters are at least partially full of oil. This is indicated by little or no plunger travel when the lash adjuster is depressed.

(2) Install cam follower assembly as previously outlined in this section.

(3) Install camshaft as previously outlined in this section.

(4) Install cylinder head cover as previously outlined in this section.

Fig. 43 Valve Spring—Removal/Installation

INSTALLATION

(1) Install valve seal/valve spring seat assembly (Fig. 44). Push the assembly down to seat it onto the valve guide.

(2) Install valve spring and retainer, use Special Tool MD-998772-A with adapter 6779 to compress valve springs only enough to install locks (Fig. 43). Correct alignment of tool is necessary to avoid nicking valve stems.

(3) Remove air hose and install spark plugs.

(4) Install camshafts as previously outlined in this section.

(5) Install cylinder head cover as previously outlined in this section.

CYLINDER HEAD

REMOVAL

(1) Perform fuel system pressure release procedure before attempting any repairs. Refer to Group 14, Fuel System for procedure.

VALVE RETAINING LOCKSVALVESPRINGVALVE SEAL ANDVALVE SPRING SEATASSEMBLYVALVE SPRINGRETAINER

STRETCHEDBOLT THREADS ARE NOT STRAIGHT ON LINETHREADS ARE STRAIGHT ON LINEUNSTRETCHEDBOLT

9 - 74 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced.

Fig. 45 Checking Bolts for Stretching (Necking)

Fig. 44 Valve Stem Seal/Valve Spring Seat

(2) Disconnect negative battery cable. Drain cooling system. Refer to Group 7, Cooling System for procedure.

(3) Remove air cleaner and disconnect all vacuum lines, electrical wiring and fuel lines from throttle body.

(4) Remove throttle linkage. Refer to Group 14, Fuel System for procedures

(5) Remove accessory drive belts. Refer to Group 7, Cooling System for procedure.

(6) Remove power brake vacuum hose from intake manifold.

(7) Raise vehicle and remove exhaust pipe from manifold.

(8) Remove power steering pump assembly and

set aside.

(9) Disconnect coil pack wiring connector and remove coil pack and plug wires from engine.

(10) Remove cam sensor and fuel injectors wiring connectors.

(11) Remove timing belt and camshaft sprocket. Refer to procedure outlined in this section.

(12) Remove timing belt idler pulley and rear timing belt cover.

(13) Remove cylinder head cover using procedure outlined in this section.

(14) Remove camshafts and cam followers. Refer to procedures outlined in this section for procedures.

(15) Remove cylinder head bolts and remove cylinder head from engine block.

(16) Inspect and clean cylinder head. Refer to Cleaning and Inspection outlined in this section for procedures.

INSTALLATION

NOTE: The Cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts should be replaced (Fig. 45).

(1) Before installing the bolts, the threads should

be coated with engine oil.

(2) Tighten the cylinder head bolts in the sequence shown in (Fig. 46). Using the 4 step torque turn method, tighten according to the following values:

• First All to 34 N·m (25 ft. lbs.)

• Second All to 68 N·m (50 ft. lbs.)

• Third All to 68 N·m (50 ft. lbs.)

CAUTION: Do not use a torque wrench for the following step.

• Fourth Turn an additional 1/4 Turn,

Fig. 46 Cylinder Head Tightening Sequence

(3) Install camshafts and cam followers. Refer to procedures outlined in this section for procedures.

(4) Install cylinder head cover using procedure outlined in this section.

(5) Install rear timing belt cover and timing belt idler pulley.

(6) Install timing belt and camshaft sprocket. Refer to procedure outlined in this section.

(7) Install cam sensor and fuel injectors wiring connectors.

VALVE SEAL TOOL VALVE STEM

SPECIALTOOL 1026 SPECIAL TOOL6827–A INSERT

GARTERSPRINGVALVESPRING SEAT CYLINDERHEAD SUR-FACE

JA 2.4L ENGINE 9 - 75

REMOVAL AND INSTALLATION (Continued)

(8) Install coil pack and plug wires onto the

engine. Connect coil pack wiring connector.

(9) Install power steering pump assembly. (10) Raise vehicle and install the exhaust pipe to

the manifold.

(11) Install power brake vacuum hose to the intake

manifold.

(12) Install accessory drive belts. Refer to Group 7,

Cooling System for procedure.

(13) Install throttle linkage. Refer to Group 14,

Fuel System for procedures.

(14) Install air cleaner and connect all vacuum lines, electrical wiring and fuel lines to the throttle body.

(15) Fill cooling system. Refer to Group 7, Cooling System for procedure. Connect negative battery cable.

VALVES AND VALVE SPRINGS

REMOVAL

(1) With cylinder head removed, compress valve springs using a universal valve spring compressor.

(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 damage to the valve guides. Identify valves to insure

installation in original location.

(4) Inspect and clean the valves. Refer to Cleaning and Inspection outlined in this section for procedure.

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. 47). The valve stem seals should be pushed firmly and squarely over valve guide.

CAUTION: When oversize valves are used, the corresponding oversize valve seal must also be used. Excessive guide wear may result if oversize seals are not used with oversize valves.

CAUTION: When depressing the valve spring retainers with valve spring compressor the locks can become dislocated. Ensure both locks are in the correct location after removing tool.

(4) Check the valve spring installed height B after refacing the valve and seat (Fig. 48). Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 in.), install a .762 mm (0.030 in.) spacer under the valve spring seat to bring spring height back within specification.

Fig. 48 Checking Spring Installed Heightand Valve

Tip Height Dimensions

VIBRATION DAMPER

REMOVAL

Remove crankshaft vibration damper bolt. Remove damper by using Special Tool 1026 and Insert 6827–A (Fig. 49).

Fig. 47 Valve Stem Oil Seal Tool

Fig. 49 Crankshaft Vibration Damper—Removal

M12–1.75 3 150 MM BOLT,WASHER AND THRUSTBEARING FROM SPECIALTOOL 6792

UPPER TIMING BOLT COVERFASTENERSENGINE SUPPORT BRACKETFASTENERSLOWER TIMING BELTCOVER FASTENERS

REAR COVER TO CYLINDERHEAD FASTENERSREAR COVER TO ENGINEBLOCK FASTENERSBELT TENSIONER

9 - 76 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

INSTALLATION

Install crankshaft vibration damper using M12

1.75 x 150 mm bolt, washer, thrust bearing and nut from Special Tool 6792. Install crankshaft vibration damper bolt and tighten to 142 N·m (105 ft. lbs.) (Fig. 50).

Fig. 50 Crankshaft Vibration Damper—Installation

TIMING BELT COVER

FRONT COVER

INSTALLATION

(1) Install the engine mount bracket and front timing belt cover (Fig. 51).

(2) Install crankshaft damper. Refer to crankshaft damper installation for procedure.

REAR COVER

REMOVAL

(1) Remove Front Cover. Refer to Front Cover Removal procedure outlined in this section.

(2) Remove Timing Belt. Refer to procedure outlined in this section.

(3) Remove idler pulleys (Fig. 52).

(4) Remove both camshaft sprockets.

(5) Remove rear timing belt fasteners and remove cover from engine (Fig. 52).

REMOVAL

(1) Remove crankshaft damper. Refer to crank-

shaft damper removal for procedure.

(2) Remove front timing belt cover fasteners (Fig.

51) and remove cover. (3) Remove engine mount bracket (Fig. 51).

Fig. 52 Rear Timing Belt Cover Fasteners

INSTALLATION

(1) Install rear timing belt cover and fasteners

(Fig. 52).

(2) Install idler (Fig. 52). (3) Install camshaft sprockets. (4) Install Timing Belt. Refer to procedure outlined

in this section.

Fig. 51 Front Timing Belt Covers

UPPER TIMING BELT COVERFASTENERSENGINE SUPPORT BRACKETFASTENERSLOWER TIMING BELTCOVER FASTENERS

CAMSHAFT TIMING MARKSTOGETHERCRANKSHAFT AT TDC

1/8 OR 3mm ALLENWRENCHBELT TENSIONER6mm ALLEN WRENCH

JA 2.4L ENGINE 9 - 77

REMOVAL AND INSTALLATION (Continued)

(5) Install front cover. Refer to Front Cover instal-

lation procedure outlined in this section.

TIMING BELT

REMOVAL

(1) Raise vehicle on hoist. Remove right front

wheel.

(2) Remove right inner splash shield. (3) Remove accessory drive belts. Refer to Group 7,

Cooling System.

(4) Remove crankshaft damper bolt, and remove

damper. Refer to Removal and Installation procedure in this section.

(5) Remove lower timing belt cover fasteners and

remove cover (Fig. 53).

(6) Lower vehicle and remove upper timing belt

cover fasteners and remove cover.

Fig. 53 Timing Belt Covers

(7) Remove right engine mount and support

bracket. Refer to Removal and Installation procedure in this section.

CAUTION: When aligning crankshaft and camshaft timing marks always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt.

(8) Align crankshaft and camshafts timing marks

(Fig. 54) to TDC.

(9) Install 6 mm Allen wrench into belt tensioner.

Before rotating the tensioner insert the long end of a

Fig. 54 Crankshaft and Camshaft Timing

Fig. 55 Locking Timing Belt Tensioner

1/8” or 3 mm Allen wrench into the pin hole on the front of the tensioner (Fig. 55). While rotating the tensioner counterclockwise push in lightly on the 1/8” or 3 mm Allen wrench, until it slides into the locking hole.

(10) Remove timing belt.

BELT TENSIONERTENSIONER BRACKETALIGNMENT FLATS

CAMSHAFT SPROCKETEXHAUSTCAMSHAFT SPROCKETINTAKE1/2 NOTCH LOCATION

9 - 78 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

TIMING BELT TENSIONER

(1) If replacing timing belt tensioner, remove the

bolt from the center of the tensioner. Remove tensioner.

(2) When installing the tensioner align the flat on

the tensioner bracket with the flat on the tensioner (Fig. 56).

(3) Torque tensioner center bolt to 28 N·m (252 in.

lbs.)

(6) Rotate crankshaft 2 revolutions and check the

alignment of the timing marks (Fig. 54).

(7) Install right engine mount and support bracket. Refer to Removal and Installation procedure in this section.

(8) Install upper timing belt cover bolts 4.5 N·m (40 in. lbs.).

(9) Install the lower timing belt cover bolts 4.5 N·m (40 in. lbs.).

(10) Install crankshaft damper. Refer to Service procedure outlined in this section.

(11) Install accessory drive belts. Refer to Group 7, Cooling System.

(12) Install right inner splash shield.

(13) Install right front wheel.

Fig. 56 Tensioner to Bracket Alignment

INSTALLATION

(1) Set crankshaft sprocket to TDC by aligning

the sprocket with the arrow on the oil pump housing.

(2) Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket (Fig. 57).

CAUTION: Ensure that the arrows on both camshaft sprockets are facing up.

(3) Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner (Fig. 58).

(4) Move the exhaust camshaft sprocket counterclockwise (Fig. 58) to align marks and take up belt slack.

NOTE: A new tensioner is held in the wound position by a pull pin.

(5) Remove the pull pin or Allen wrench from the belt tensioner.

Fig. 57 Camshaft Sprocket Alignment

TIMING BELT TENSIONER

For Removal and Installation procedure for belt tensioner. Refer to Timing Belt Removal and Installation in this section.

OIL PAN

REMOVAL

(1) Drain engine oil.

(2) Remove engine support module. Refer to Removal and Installation procedure in this section.

(3) Remove collar from rear of pan and transmission.

(4) Remove oil pan.

(5) Clean oil pan and all gasket surfaces.

INSTALLATION

(1) Apply Mopar Silicone Rubber Adhesive Sealant or equivalent at the oil pump to engine block parting line (Fig. 59).

(2) Install the oil pan gasket to the block (Fig.

60).

(3) Install pan and tighten the screws to 12 N·m (105 in. lbs.).

MOVE CAMSHAFTSPROCKET TO TAKE UPBELT SLACKCAMSHAFT TIMING MARKS1/2 NOTCH LOCATIONCRANKSHAFT AT TDCINSTALL BELT IN THISDIRECTION

PLACE A 3 MM (1/8 INCH) BEAD OFSEALANT AT THE PARTING LINE OF THEOIL PUMP BODY TO ENGINE BLOCK

OIL PICK-UP TUBE OIL PAN GASKETWITH WINDAGETRAYSEALER

ADAPTERC-4687–1SPECIAL TOOL C-4687

JA 2.4L ENGINE 9 - 79

REMOVAL AND INSTALLATION (Continued)

Fig. 60 Oil Pan Gasket Installation

(6) Install the 2 remaining collar to pan bolts. Starting with the center bolts and working outward torque all 4 bolts to 34 N·m (250 in. lbs.).

(7) Install engine support module. Refer to Removal and Installation procedure in this section.

Fig. 58 Timing Belt—Installation

Fig. 59 Oil Pan Sealing

CAUTION: Torque procedure for the collar must be followed or damage could occur to oil pan or collar.

(4) Install the 2 center collar to oil pan bolts.

Torque to 3 N·m (30 in. lbs.)

(5) Install collar to transmission bolts and tighten

to 108 N·m (80 ft. lbs.).

FRONT CAMSHAFT OIL SEAL

REMOVAL

(1) Remove front timing belt cover and timing belt. Refer to procedure outlined in this section.

(2) Hold camshaft sprocket with Special Tool C-4687 and adapter C-4687-1 while removing center bolt (Fig. 61).

(3) Remove camshaft seal using Special Tool C-4679-A (Fig. 62).

Fig. 61 Camshaft Sprocket—Removal/Installation

CAUTION: Do not nick shaft seal surface or seal bore

INSTALLATION

(1) Shaft seal surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary.

(2) Install camshaft seal into cylinder head using Special Tool MD-998306 until flush with head (Fig.

63).

SPECIAL TOOL C-4679

SPECIAL TOOLMD 998306

SPECIALTOOL 1026 SPECIAL TOOL6827–A INSERT

SPECIAL TOOL6793CRANKSHAFT SPROCKET

SPECIAL TOOL6771REAR TIMING BELT COVER

9 - 80 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

Fig. 62 Camshaft Oil Seal—Removal WithC-4679–A

Fig. 63 Camshaft Seal—Installation

(3) Install camshaft sprocket and tighten center

bolt to 101 N·m (75 ft. lbs.) (Fig. 61).

FRONT CRANKSHAFT OIL SEAL

REMOVAL

(1) Using large side of Special Tool 1026 and

Insert 6827-A, remove crankshaft damper (Fig. 64).

(2) Remove outer timing belt cover and timing belt. Refer to Timing Belt System outlined in this section.

(3) Remove crankshaft sprocket using Special Tool 6793 and insert C-4685-C2 (Fig. 65).

Fig. 64 Crankshaft Damper—Removal

Fig. 65 Crankshaft Sprocket—Removal

CAUTION: Do not nick shaft seal surface or seal bore.

(4) Using Tool 6771 to remove front crankshaft oil seal (Fig. 66). Be careful not to damage the seal surface of cover.

Fig. 66 Front Crankshaft Oil Seal—Removal

INSTALLATION

(1) Install new seal by using Tool 6780 (Fig. 67).

PROTECTORSEALSPECIAL TOOL6780

SPECIAL TOOL6792TIGHTEN NUT TO INSTALL

M12–1.75 3 150 MM BOLT,WASHER AND THRUSTBEARING FROM SPECIALTOOL 6792

JA 2.4L ENGINE 9 - 81

REMOVAL AND INSTALLATION (Continued)

(2) Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover.

(3) Install crankshaft sprocket (Fig. 68). Using Special Tool 6792.

(4) Install timing belt and timing belt covers. Refer to Timing System Section for timing belt covers and belt.

(5) Install crankshaft damper (Fig. 69). Use thrust bearing/washer and 12M 1.75 x 150 mm bolt from Special Tool 6792. Install crankshaft damper bolt and tighten to 142 N·m (105 ft. lbs.)

Fig. 68 Crankshaft Sprocket—Installation

Fig. 67 Front Crankshaft Oil Seal—Installation

REAR CRANKSHAFT SEAL

REMOVAL

CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted.

Fig. 69 Crankshaft Damper—Installation

INSTALLATION

CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation 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. 76).

CAUTION: If the seal is driven into the block past flush, this may cause an oil leak.

REAR CRANKSHAFTSEAL ENGINEBLOCK ENGINE BLOCKREAR CRANK-SHAFT SEALMETAL CASEPRY IN THISDIRECTIONCRANK-SHAFTSCREW-DRIVERREAR CRANKSHAFT SEALDUST LIPSCREW-DRIVER

SPECIAL TOOL 6926–1PILOT SEAL

SPECIALTOOL6926–1PILOT

SPECIAL TOOL6792–2 INSTALLER

SPECIALTOOL6926–2INSTALLER

SEAL

9 - 82 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

Fig. 70 Rear Crankshaft Oil Seal—Removal

(3) Drive the seal into the block using Special Tool 6926-2 and handle C-4171 (Fig. 77) until the tool bottoms out against the block (Fig. 78).

Fig. 72 Crankshaft Seal Special Tool 6926-2

Fig. 71 Rear Crankshaft Seal and SpecialTool 6926-1

CRANKSHAFT

REMOVAL

NOTE: Crankshaft can not be removed when engine is in vehicle.

Fig. 73 Rear Crankshaft Seal—Installation

(1) Remove oil filter and oil pan. Refer to proce-

dure outlined in this section.

(2) Remove Timing Belt Cover, Timing Belt and

Oil Pump. Refer to procedure outlined in this section.

LUBRICATION GROOVESOIL HOLES

FRONTOFENGINE

JA 2.4L ENGINE 9 - 83

REMOVAL AND INSTALLATION (Continued)

(3) Remove Balance Shafts Assembly. Refer to procedure outlined in this section.

(4) Remove all main bearing cap bedplate bolts from the engine block. Refer to procedure outlined in this section.

(5) Using a mallet gently tap the bedplate loose from the engine block dowel pins.

CAUTION: Do not pry up on one side of the bedplate. Damage may occur to cylinder block to bedplate alignment and thrust bearing.

(6) Bedplate should be removed evenly from the cylinder block dowel pins to prevent damage to the dowel pins and thrust bearing.

(7) Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft.

INSTALLATION

(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of Mopar Torque Cure Gasket Maker to cylinder block as shown in (Fig. 75).

Fig. 75 Main Bearing Caps/Bedplate Sealing

Fig. 74 Installing Main Bearing Upper Shell

(1) Install the main bearing shells with the lubri-

cation groove in the cylinder block (Fig. 74).

(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 may effect the sealer ability to seal the bedplate to cylinder block.

(3) Oil the bearings and journals. Install crankshaft.

CAUTION: Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine.

Fig. 76 Main Bearing Caps/Bedplate

TorqueSequence

(5) Install lower main bearings into main bearing cap/bedplate. Make certain the bearing tabs are seated into the bedplate slots. Install the main bearing/bedplate into engine block.

(6) Before installing the bolts the threads should be oiled 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 this bolts down together until the bedplate contacts the cylinder block. Then torque these bolts to 28 N·m (20 ft. lbs.).

(8) Install main bearing bedplate to engine block bolts (1 thru 10) and torque each bolt to 41 N·m (30 ft. lbs.) in sequence, then in sequence tighten bolts an additional 1/4 turn (Fig. 76).

OIL PAN GASKET WITHWINDAGE TRAYO-RINGOIL PUMP BODYFILTEROIL PICK-UP TUBEDRAIN PLUGOIL PANCOLLAR

SPECIAL TOOL6793CRANKSHAFT SPROCKET

9 - 84 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

(9) Install main bearing bedplate to engine block bolts (11 thru 20), and torque each bolt to 28 N·m (20 ft. lbs.) in sequence shown in (Fig. 76).

(10) After the main bearing bedplate is installed, check the crankshaft turning torque. The turning torque should not exceed 5.6 N·m (50 in. lbs.).

OIL FILTER

CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock seam. The lock seam joining the can to the base is reinforced by the base plate.

(1) Turn counterclockwise to remove.

(2) To install, lubricate new filter gasket. Check filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. Screw filter on until the gasket contacts base. Tighten to 21 N·m (15 ft. lbs.).

OIL PUMP

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove Timing Belt. Refer to Timing Belt Removal in this section.

(3) Remove collar and Oil Pan. Refer to Oil Pan

Removal in this section.

(4) Remove Crankshaft Sprocket using Special Tool

6793 and insert C-4685-C2 L (Fig. 77).

Fig. 77 Crankshaft Sprocket—Removal

(5) Remove oil pick-up tube. (6) Remove oil pump, (Fig. 78) and front crank-

shaft seal.

Fig. 78 Oil Pump and Pick-up Tube

APPLY GASKETMAKER TO OILPUMP BODY FLANGE

PROTECTORSEALSPECIAL TOOL6780

SPECIAL TOOL6792TIGHTEN NUT TO INSTALL

JA 2.4L ENGINE 9 - 85

REMOVAL AND INSTALLATION (Continued)

INSTALLATION

(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. 79). Install oil ring into oil pump body discharge passage.

Fig. 79 Oil Pump Sealing

(3) Prime oil pump before installation.

(4) Align oil pump rotor flats with flats on crankshaft 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) Install new front crankshaft seal using Special Tool 6780 (Fig. 80).

(6) Install crankshaft sprocket, using Special Tool 6792 (Fig. 81).

(7) Install oil pump pick-up tube and oil pan.

CAUTION: Torque procedure for the collar must be followed or damage could occur to oil pan or collar.

(8) Install the 2 center collar to oil pan bolts. Torque to 3 N·m (30 in. lbs.)

(9) Install collar to transmission bolts and tighten to 108 N·m (80 ft. lbs.).

(10) Install the 2 remaining collar to pan bolts. Starting with the center bolts and working outward torque all 4 bolts to 34 N·m (250 in. lbs.).

(11) Install Timing Belt. Refer to Timing Belt Installation in this section.

PISTON AND CONNECTING ROD

REMOVAL

NOTE: Cylinder Head must be removed before Pistons and Rods. Refer to Cylinder Head Removal in this section.

Fig. 80 Front Crankshaft Seal—Installation

Fig. 81 Crankshaft Sprocket—Installation

(2) Remove oil pan. Scribe the cylinder number on the side of the rod and cap (Fig. 83) for identification.

(3) Pistons have a directional stamping in the front half of the piston facing towards the front of engine.

DIRECTIONAL ARROW WILL BEIMPRINTED IN THIS AREA

GAP OF LOWERSIDE RAIL NO. 1 RING GAPGAP OF UPPERSIDE RAILNO. 2 RING GAP ANDSPACER EXPANDERGAP FRONT OF ENGINE

9 - 86 2.4L ENGINE JA

REMOVAL AND INSTALLATION (Continued)

Fig. 82 Piston Markings

(4) Pistons and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each connecting rod is centered in cylinder bore.

(5) Remove Balance Shaft Assembly. Refer to Balance Shaft Removal in this section.

(6) Remove connecting rod cap bolts. Push each piston and rod assembly out of cylinder bore.

Fig. 84 Piston Ring End Gap Position

NOTE: Be careful not to nick crankshaft journals.

(7) After removal, install bearing cap on the mating rod.

(8) Piston and Rods are serviced as an assembly.

Fig. 83 Identify Connecting Rod to Cylinder

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. 84). As viewed from top.

(3) Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston (Fig. 85). Be sure position of rings does not change during this operation .

Fig. 85 Piston—Installation

(4) The directional stamp on the piston should

face toward the front of the engine (Fig. 82).

(5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal.

(6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal.

NOTE: The rod bearing bolts should not be reused.

(7) Before installing the NEW bolts the threads should be coated with clean engine oil.

(8) Install each bolt finger tight than alternately torque each bolt to assemble the cap properly.

CAUTION: Do not use a torque wrench for second part of last step.

(9) Tighten the bolts to 27 N·m PLUS 1/4 turn (20 ft. lbs. PLUS 1/4 turn)

OIL PAN GASKET WITHWINDAGE TRAYO-RINGOIL PUMP BODYFILTEROIL PICK-UP TUBEDRAIN PLUGOIL PANCOLLAR

JA 2.4L ENGINE 9 - 87

REMOVAL AND INSTALLATION (Continued)

(10) Using a feeler gauge, check connecting rod

side clearance (Fig. 86).

Fig. 86 Checking Connecting Rod Side Clearance

DISASSEMBLY AND ASSEMBLY

OIL PUMP

DISASSEMBLY

(1) To remove the relief valve, proceed as follows:

(a) Remove the threaded plug and gasket from

the oil pump (Fig. 87).

(b) Remove spring and relief valve (Fig. 87)

(2) Remove oil pump cover screws, and lift off cover.

(3) Remove pump rotors.

(4) Wash all parts in a suitable solvent and inspect carefully for damage or wear.

ASSEMBLY

(1) Assemble pump, using new parts as required.

Install the inner rotor with chamfer facing the cast iron oil pump cover.

(2) Prime oil pump before installation by filling rotor cavity with engine oil.

(3) Install cover and tighten screws to 12 N·m (105 in. lbs.).

CAUTION: Oil pump pressure relief valve must be installed as shown in (Fig. 87) or serious damage may occur.

(4) Install relief valve, spring, gasket and cap as shown in (Fig. 87). Tighten cap to 41 N·m (30 ft. lbs.)

Fig. 87 Oil Pressure Relief Valve

FEELERGAUGE STRAIGHTEDGE

TOPMIDDLEBOTTOM CUT AWAY VIEW OFVALVE GUIDE MEA-SUREMENT LOCA-TIONS

VALVE GUIDESPRING HEAT13.25 - 13.75 MM(.521 - .541 IN.)

9 - 88 2.4L ENGINE JA

CLEANING AND INSPECTION

CYLINDER HEAD

CLEANING

Remove all gasket material from cylinder head and block. Be careful not to gouge or scratch the aluminum head sealing surface.

INSPECTION

(1) Cylinder head must be flat within 0.1 mm (0.004 inch) (Fig. 88).

(2) Inspect camshaft bearing journals for scoring.

Fig. 90 Valve Guide Specifications

Fig. 88 Checking Cylinder Head Flatness

VALVE GUIDES

(1) Remove carbon and varnish deposits from

inside of 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 bottom (Fig. 89). Refer to (Fig. 90) for specifications. Replace guides if they are not within specification.

(3) Check valve guide height (Fig. 91).

Fig. 89 Checking Wear on Valve Guide—Typical

VALVE AND VALVE SPRING

VALVES

(1) Clean valves thoroughly and discard burned, warped and cracked valves.

Fig. 91 Valve Guide Height

(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

(.002 in.), replace valve.

VALVE SPRINGS

(1) Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct tension. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs:

• Valve Closed Nominal Tension— 76 ft. lbs. @

38.0 mm (1.50 in.)

• Valve Open Nominal Tension— 136 ft. lbs. @

29.75 mm (1.17 in.)

(2) Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring.

OIL PUMP

(1) Clean all parts thoroughly. Mating surface of the oil pump should be smooth (Fig. 92). Replace pump cover if scratched or grooved.

O-RINGSEALINNER ROTOR ROTOROIL PUMP COVERFASTENEROUTER ROTOROIL PUMP BODY

STRAIGHTEDGE FEELERGAUGEOIL PUMP COVER

JA 2.4L ENGINE 9 - 89

CLEANING AND INSPECTION (Continued)

(2) Lay a straightedge across the pump cover surface (Fig. 93). If a .076 mm (.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 9.40 mm (0.370 inch.) or less (Fig. 94), or if the diameter is 79.95 mm (3.148 inches.) or less, replace outer rotor.

(4) If inner rotor measures 9.40 mm (.370 inch.) or less replace inner rotor (Fig. 95).

(6) Install inner rotor into pump housing. If clearance between inner and outer rotors (Fig. 97) is .203 mm (.008 inch) or more, replace both rotors.

(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.

Fig. 92 Oil Pump

Fig. 93 Checking Oil Pump Cover Flatness

(5) Slide outer rotor into pump housing, press to one side with fingers and measure clearance between rotor and housing (Fig. 96). If measurement is 0.39 mm (0.015 inch.) or more, replace housing only if outer rotor is in specification.

Fig. 94 Measuring Outer Rotor Thickness

Fig. 95 Measuring Inner Rotor Thickness

FEELERGAUGEOUTERROTOR

FEELERGAUGE STRAIGHTEDGE

FEELERGAUGEINNERROTOROUTERROTOR

9 - 90 2.4L ENGINE JA

CLEANING AND INSPECTION (Continued)

(10) If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss.

Fig. 96 Measuring Outer Rotor Clearance inHousing

CRANKSHAFT

The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 99). Limits of taper or out of round on any crankshaft journals should be held to .025 mm (.001 inch). Journal grinding should not exceed .305 mm (.012 inch) 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 polish after any journal regrind be in the same direction as normal rotation in the engine.

Fig. 97 Measuring Clearance Between Rotors

Fig. 98 MeasuringClearance Over Rotors

Fig. 99 Crankshaft Journal Measurements

CYLINDER BLOCK

(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 outlined in this section.

(3) Examine block and cylinder bores for cracks or fractures.

CYLINDER BORE INSPECTION

The cylinder walls should be checked for out-ofround and taper with Tool C119 (Fig. 100). The cylinder bore out-of-round is 0.050 mm (.002 inch) maximum and cylinder bore taper is 0.051 mm (0.002 inch) maximum. If the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.

Measure the cylinder bore at three levels in directions A and B (Fig. 100). Top measurement should be 10 mm (3/8 in.) down and bottom measurement should be 10 mm (3/8 in.) up from bottom of bore. Refer to (Fig. 101) for specifications.

FRONT MIDDLEOF BORE

TIP LASH ADJUSTERPOCKETROLLER

USE FOR SIZING

PISTON

JA 2.4L ENGINE 9 - 91

CLEANING AND INSPECTION (Continued)

ADJUSTMENTS

ENGINE SUPPORT ADJUSTMENT

The right and left support assemblies are slotted to allow for right/left drive train adjustment in relation to drive shaft assembly length.

Check and reposition right and left engine support assemblies as required. Adjust drive train position, if required, for the following conditions:

• Drive shaft distress: See Group 2, Suspension

and Driveshaft.

• Any front end structural damage (after repair).

• Support Assembly replacement.

ENGINE SUPPORT ADJUSTMENT

(1) Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack.

(2) Loosen the right engine support assembly vertical fasteners.

(3) Loosen the left engine support assembly vertical bolts.

Fig. 100 Checking Cylinder Bore Size

(5) Tighten right engine support assembly vertical bolts to 61 N·m (45 ft. lbs.). and tighten left engine support assembly bolts to 61 N·m (45 ft. lbs.).

(6) Recheck drive shaft length.

Fig. 101 Cylinder Bore and Piston Specifications

CAMSHAFT FOLLOWER

Inspect the cam follower assembly for wear or

damage (Fig. 102). Replace as necessary.

Fig. 102 Cam Follower Assembly

9 - 92 2.4L ENGINE JA

SPECIFICATIONS

ENGINE 2.4L

Type ...................In-Line OHV, DOHC

Number of Cylinder ......................4

Bore ....................87.5 mm (3.445 in.)

Stroke ...................101mm(3.976 in.)

Compression Ratio ....................9.4:1

Displacement ......2.4Liters (148 Cubic Inches)

Firing Order ......................1,3,4,2

Compression Pressure ..........1172-1551 kPa

(170-225 psi)

Maximum Variation Between Cylinder .....25%

Lubrication . . . Pressure Feed-Full Flow Filtration

(Direct Crankshaft Driven Pump)

Engine Oil Capacity ...........WithOilFilter

4.25 Liters (4.5 Qts.)

Engine Oil Capacity .........Without Oil Filter

3.8 Liters (4.0 Qts.)

Cylinder Block

Cylinder Bore Diameter . . . 87.4924 - 87.5076 mm

(3.4446 - 3.4452 in.)

Out-of-Round (Max.) .......0.051 mm (0.002 in.)

Taper (Max.) .............0.051 mm (0.002 in.)

Pistons

Clearance at 14 mm (9/16 in.)

From Bottom of Skirt ........0.024 - 0.057 mm

(0.0009 - 0.0022 in.)

Weight ......332-346grams (11.85 - 12.20 oz.)

Top Land Clearance

(Diametrical) ...............0.614 - 0.664 mm

(0.024 - 0.026 in.)

Piston Length ............60.30 mm (2.374 in.)

Piston Ring Groove Depth

No.1 .......4.640 - 4.784 mm (0.182 - 0.188 in.)

No.2 .......4.575 - 4.719 mm (0.180 - 0.185 in.)

No.3 .......4.097 - 4.236 mm (0.161 - 0.166 in.)

Piston Pins

Clearance in Piston ..........0.005 - 0.018 mm

In Rod (Interference) .........0.018 - 0.043 mm

(0.0007 - 0.0017 in.)

Diameter .................21.998-22.003 mm

(0.8660 - 0.8662 in.)

End Play ............................None

Length ....................72.75 - 73.25 mm

(2.864 - 2.883 in.)

Piston Ring Gap

Top Compression Ring ..........0.25 - 0.51 mm

(0.0098 - 0.020 in.)

2nd Compression Ring .........0.23 - 0.48 mm

(0.009 - 0.018 in.)

Oil Control (Steel Rails) ........0.25 - 0.64 mm

(0.0098 - 0.025 in.)

Piston Ring Side Clearance

Top and Second Compression

Rings ....................0.030 - 0.080 mm

(0.0011 - 0.0031 in.)

Oil Ring (Pack) .............0.012 - 0.178 mm

(0.0004 - 0.0070 in.)

Piston Ring Width

Compression Rings ............1.47 - 1.50 mm

(0.057 - 0.059 in.)

Oil Ring (Pack) ...............2.72 - 2.88 mm

(0.107 - 0.1133 in.)

Connecting Rod

Bearing Clearance ...........0.025 - 0.071 mm

(0.0009 - 0.0027 in.)

Piston Pin Bore Diameter .....20.96 - 20.98 mm

(0.8252 - 0.8260 in.)

Large End Bore Diameter . . . 53.007 - 52.993 mm

(2.0868 - 2.0863)

Side Clearance .............0.013 - 0.0150 mm

(0.0051 - 0.0150 in.)

Total Weight (Less Bearing) .......565.8 grams

(19.96 oz.)

Crankshaft

Connecting Rod Journal

Diameter ..............49.984 - 50.000 mm

(1.967 - 1.9685 in.)

Out-of-Round (Max.) .....0.0035 mm (0.0001 in.)

Taper (Max.) ...........0.0038 mm (0.0001 in.)

Main Bearing Diametrical

Clearance No.1-5 ........0.018 - 0.058 mm

(0.0007 - 0.0023 in.)

End Play ....0.09 - 0.24 mm (0.0035 - 0.0094 in.)

Main Bearing Journals

Diameter ................59.992 - 60.008 mm

(2.361 - 2.3625 in.)

Out-of-Round (Max.) .....0.0035 mm (0.0001 in.)

Taper (Max.) ..............0.0038 (0.0001 in.)

Hydraulic Lash Adjusters

Body Diameter ............15.901 - 15.913 mm

(0.626 - 0.6264 in.)

Plunger Travel Minimum (Dry) .........3.0mm

(0.118 in.)

JA 2.4L ENGINE 9 - 93

SPECIFICATIONS (Continued)

Camshaft

Bearing Bore Diameter

No.1-6 .................26.020 - 26.041 mm

(1.024 - 1.025 in.)

Diametrical Bearing Clearance . . . 0.069 - 0.071 mm

(0.0027 - 0.003 in.)

End Play ....................0.050 - 0.170 mm

(0.0019 - 0.0066 in.)

Bearing Journal Diameter

No.1-6 .................25.951 - 25.970 mm

(1.021 - 1.022 in.)

Lift (Zero Lash) Intake .......8.25 mm (0.324 in.)

Exhaust ...................6.52 mm (0.256 in.)

Valve Timing

Intake Valve Closes (ABDC) ................51°

Opens (BTDC) ...........................5°

Duration ..............................236°

Exhaust Valve Closes (ATDC) ...............10°

Opens (BBDC) ..........................50°

Duration ..............................240°

Valve Overlap ...........................15°

Cylinder Head

Material .....................Cast Aluminum

Gasket Thickness

(Compressed) .....................1.15 mm

(0.045 in.)

Valve Seat Angle .........................45°

Runout (Max.) .............0.050 mm (0.002 in.)

Width (Finish) Intake

and Exhaust ...................0.9-1.3 mm

(0.035 - 0.051 in.)

Guide Bore Diameter (Std) .......11.0-11.02 mm

Finished Guide Bore ID ........5.975 - 6.000 mm

Valves

Face Angle Intake and Exhaust ........45-44

Head Diameter Intake .........34.67 - 34.93 mm

Exhaust ......30.37 - 30.63 mm (1.195 - 1.205 in.)

Length (Overall) Intake .......112.76 - 113.32 mm

Exhaust ...................109.59 -110.09 mm

Stem Diameter Intake .........5.934 - 5.952 mm

(0.4330 - 0.4338 in.)

(0.235 - 0.236 in.)

(1.364 - 1.375 in.)

(4.439 - 4.461 in.) (4.314 - 4.334 in.) (0.233 - 0.234 in.)

⁄2°

Exhaust ......5.906 - 5.924 mm (0.233 - 0.233 in.)

Valve Margin Intake ...........1.285 - 1.615 mm

(0.050 - 0.063 in.)

Exhaust ....................0.985 - 1.315 mm

(0.038 - 0.051 in.)

Valve Stem Tip Height

Intake .................48.04 mm (1.891 in.)

Exhaust ..................47.99 mm (1.889 in.)

Stem Diameter Intake .........5.934 - 5.952 mm

(0.234 - 0.234 in.)

Exhaust ....................5.906 - 5.924 mm

(0.233 - 0.233 in.)

Stem-to-Guide Clearance

Intake ....................0.048 - 0.066 mm

(0.0018 - 0.0025 in.)

Exhaust ....................0.0736 - 0.094 mm

(0.0029 - 0.0037 in.)

Max. Allowable Intake and

Exhaust ........................0.025 mm

(0.010 in.)

Valve Springs

Free Length (Approx.) ........48.4 mm (1.905 in.)

Spring Tension

(Valve Closed) .......338N620 N @ 38.0 mm

(75.98 lbs. 6 4.5 lbs. @ 1.496 in.)

Spring Tension

(Valve Open) .......607N630 N @ 29.75 mm

(136 lbs. 6 7 lbs. @ 1.172 in.)

Number of Coils ........................7.82

Wire Diameter ..............3.86 mm (0.151 in.)

Installed Spring Height ......38.00 mm (1.496 in.)

Oil Pump

Clearance over Rotors (Max.) . . . 0.10 mm (0.004 in.)

Cover Out-of-Flat (Max.) .....0.025 mm (0.001 in.)

Inner Rotor Thickness (Min.) . . . 9.40 mm (0.370 in.) Outer Rotor Clearance (Max.) . . 0.39 mm (0.015 in.)

Diameter (Min.) ............79.95 mm (3.148 in.)

Thickness (Min.) ............9.40 mm (0.370 in.)

Tip Clearance between

Rotors (Max.) .....................0.20 mm

(0.008 in.)

Oil Pressure

At Curb Idle Speed* ..............25kPa(4psi)

At 3000 rpm ........170—550kPa(25—80psi)

9 - 94 2.4L ENGINE JA

SPECIFICATIONS (Continued)

TORQUE CHART 2.4L

DESCRIPTION ...................TORQUE

Balance Shaft Carrier to Block

Bolts ......................54N·m(40ft.lbs.)

Balance Shaft Gear Cover

Double Ended Fastener ......12N·m(105 in. lbs.)

Balance Shaft Sprockets

Bolts ....................28N·m(250 in. lbs.)

Balance Shaft Chain Tensioner

Bolts ....................12N·m(105 in. lbs.)

Balance Shaft Carrier Cover

Fasteners .................12N·m(105 in. lbs.)

Camshaft Sensor Pick Up

Bolts ....................27N·m(20ft.lbs.)

Timing Belt Cover

Outer to Inner Attaching

Bolts M6 ................4.5N·m(40in.lbs.)

Inner Cover to Head/Oil Pump

Bolts M6 ...............12N·m(105 in. lbs.)

Camshaft Sprocket

Bolt ....................101N·m(75ft.lbs.)

Connecting Rod Cap

Bolts ....................27N·m(20ft.lbs.)

Plus 1/4 Turn

Crankshaft Main Bearing Cap/Bedplate

M8 Bedplate Bolts ........34N·m(250 in. lbs.)

Main Cap Bolts M11 ........41N·m(30ft.lbs.)

Plus 1/4 Turn

Crankshaft Damper

Bolt ...................135N·m(100 ft. lbs.)

Cylinder Head

Bolts .....................Refer To Cylinder

Head Installation

Cylinder Head Cover

Bolts ...................12N·m(105 in. lbs.)

Engine Mount Bracket

Bolts ....................41N·m(30ft.lbs.)

Exhaust Manifold to Cylinder Head

Bolts ...................23N·m(200 in. lbs.)

Exhaust Manifold Heat Shield

Bolts ...................12N·m(105 in. lbs.)

Front Torque Bracket—2.0/2.4L Engine

Bolts ....................33N·m(24ft.lbs.)

Front Torque Bracket Strut—2.0/2.4L Engine

Long Bolts ...............110N·m(80ft.lbs.)

Short Bolt ................61N·m(45ft.lbs.)

Intake Manifold

Bolts ....................27N·m(20ft.lbs.)

Oil Filter

Filter ....................20N·m(15ft.lbs.)

Oil Pan

Bolts ...................12N·m(105 in. lbs.)

Drain Plug ...............27N·m(20ft.lbs.)

Oil Pan Collar

Collar to Pan Bolts ........34N·m(250 in. lbs.)

Collar to Transmission

Bolts ...................108N·m(80ft.lbs.)

Oil Pump Attaching

Bolts ...................28N·m(250 in. lbs.)

Oil Pump Cover Fastener . . . 12 N·m (105 in. lbs.) Oil Pump Pick-up Tube

Bolt ...................28N·m(250 in. lbs.)

Oil Pump Relief Valve

Cap.....................41N·m(30ft.lbs.)

Rear Torque Bracket

Bolts ...................110N·m(80ft.lbs.)

Spark Plugs

Plugs ....................28N·m(20ft.lbs.)

Support Module—Front and Rear

Thru Bolt ................61N·m(45ft.lbs.)

Thermostat Housing

Bolts ...................23N·m(200 in lbs.)

Timing Belt Tensioner

Center Bolt ..............28N·m(252 in. lbs.)

Water Pump Mounting

Bolts ...................12N·m(105 in. lbs.)

JA 2.4L ENGINE 9 - 95

SPECIAL TOOLS

ENGINE 2.4L

Cradle 6710

Puller 1026

Crankshaft Damper Removal Insert6827-A

Dolly 6135

Post Kit Engine Cradle 6848

Camshaft Sprocket Remover C-4687

Camshaft Seal Remover C-4679-A

9 - 96 2.4L ENGINE JA

SPECIAL TOOLS (Continued)

Camshaft Seal Installer MD-998306

Crankshaft Damper Installer 6792

Valve Spring Compressor MD-998772-A

Cylinder Bore Gage C-119

Crankshaft Sprocket Remover 6793

Crankshaft Sprocket Remover InsertC-4685-C2

Valve Spring Compressor Adapter 6779

Crankshaft Seal Remover 6771

JA 2.4L ENGINE 9 - 97

SPECIAL TOOLS (Continued)

Post Adapter 8130

Oil Pressure Gage C-3292

Front Crankshaft Oil Seal Installer6780

Rear Crankshaft Seal Guide and Installer6926-1 and

6926-2

Balance Shaft Sprocket Installer6052

Post Kit Engine Cradle 6848

9 - 98 2.5L ENGINE JA

2.5L ENGINE

INDEX

page page

DESCRIPTION AND OPERATION

ENGINE COMPONENTS ................ 100

ENGINE IDENTIFICATION ................ 99

ENGINE LUBRICATION SYSTEM .......... 100

GENERAL SPECIFICATION .............. 100

DIAGNOSIS AND TESTING

CHECKING ENGINE OIL PRESSURE ....... 101

SERVICE PROCEDURES

BORING CYLINDER .................... 101

CAMSHAFT END PLAY ................. 106

CONNECTING ROD CLEARANCE ......... 104

CRANKSHAFT END PLAY ............... 106

FITTING MAIN BEARINGS ............... 104

FITTING PISTON RINGS ................ 102

FITTING PISTONS ..................... 102

PISTON RINGS ....................... 103

REMOVAL AND INSTALLATION

CAMSHAFT OIL SEAL .................. 118

CAMSHAFT SPROCKETS ............... 118

CAMSHAFT .......................... 112

CRANKSHAFT DAMPER ................ 115

CRANKSHAFT ........................ 120

CYLINDER HEAD COVER ............... 110

CYLINDER HEAD ...................... 110

ENGINE ASSEMBLY .................... 108

ENGINE MOUNT—RIGHT/ENGINE SUPPORT

BRACKET .......................... 107

ENGINE SUPPORT MODULE (FRONT AND

REAR MOUNTS) ..................... 106

FRONT CRANKSHAFT OIL SEAL .......... 119

LEFT SIDE MOUNT .................... 107

OILFILTER .......................... 123

OILPAN ............................. 119

OIL PUMP ........................... 123

PISTON AND CONNECTING ROD ......... 124

REAR CRANKSHAFT SEAL AND RETAINER . 123 ROCKER ARM AND HYDRAULIC ADJUSTER . 111

TIMING BELT COVERS ................. 115

TIMING BELT ......................... 116

VALVE AND VALVE SEALS—HEAD OFF .... 113

VALVE SPRINGS AND SEALS IN VEHICLE . . 113

DISASSEMBLY AND ASSEMBLY

OIL PUMP ........................... 126

ROCKER ARMS ....................... 126

CLEANING AND INSPECTION

AUTO LASH ADJUSTER ................ 129

CAMSHAFT INSPECTION ............... 127

CYLINDER BORE AND BLOCK ........... 127

CYLINDER HEAD COVER ............... 128

CYLINDER HEAD ...................... 127

OIL FILTER BRACKET .................. 129

OIL PUMP ........................... 129

TIMING BELT INSPECTION .............. 130

VALVES, SPRINGS, SEATS AND GUIDES . . . 130

ADJUSTMENTS

ENGINE SUPPORT ADJUSTMENT ......... 132

SPECIFICATIONS

ENGINE 2.5L ......................... 132

TORQUE CHART 2.5L .................. 134

SPECIAL TOOLS

ENGINE 2.5L ......................... 135

OILFILTERENGINESERIAL NUMBERAND VIN NUMBER

JA 2.5L ENGINE 9 - 99

DESCRIPTION AND OPERATION

ENGINE IDENTIFICATION

The engine identification number is located on the rear of the cylinder block just below the cylinder head (Fig. 1).

Fig. 1 Engine Identification

ENGINE—2.5L

CYLINDER WALLS SPLASH LUBRI-CATED FROM DIRECTED HOLES INCONNECTING RODS CYLINDER HEADBOLTS CAMSHAFT JOURNALS FILTERMAIN GAL-LERYRELIEF VALVEPUMPPICKUPCAMSHAFT JOUR-NALS* NO. 2 CAMSHAFT CAP (FRONT AND REAR) RECEIVES OILFROM CYLINDER HEAD TO SUPPLY ROCKERS, LASHADJUSTERS, CAMSHAFT JOURNALS

9 - 100 2.5L ENGINE JA

DESCRIPTION AND OPERATION (Continued)

GENERAL SPECIFICATION

2.5L V-6 ENGINE

Type ..................60°V SOHC (Per Bank)

Bore .....................83.5 mm (3.29 Inch)

Stroke ...................76.0 mm (2.992 Inch)

Compression Ratio ......................9.4:1

Displacement .........2.5Liters (152 Cubic Inch)

Firing Order ....................1–2–3–4–5–6

Lubrication ....Pressure Feed-Full Flow Filtration

(Direct Crankshaft Driven Pump)

Engine Oil Capacity .................4.25 Liter

(4.5 Qts.) Including Oil

Filter, 3.8 Liter

(4.0 Qts.) Without Filter.

Cooling System . . . Liquid Cooled-Forced Circulation

(Pump-Timing Belt Driven)

Cylinder Block ......................Cast Iron

Crankshaft ............Cast (Nodular Cast Iron)

Cylinder Head ................Aluminum Alloy

Connecting Rods ..................Forged Steel

Pistons ...............Aluminum Alloy (w/Strut)

ENGINE LUBRICATION SYSTEM

The lubrication system is a full flow filtration pressure feed type. Oil, stored in the oil pan, is taken in and discharged by a trochoid type oil pump directly coupled to the crankshaft and its pressure is regu-

lated by a relief valve. The oil is fed through an oil filter and to the crankshaft journals from the oil gallery in the cylinder block. This gallery also feeds oil under pressure to the cylinder heads and camshaft journals. It then flows from the cylinder head passages to the rocker shafts to the rocker arm pivots and auto lash adjusters (Fig. 2).

ENGINE COMPONENTS

BLOCK

The cylinder block is a partial open deck design to improve cooling and weight reduction. High rigidity is provided with ribs cast in the outer wall, and a monoblock or beam type main bearing cap system. This single unit four bearing cap is designed to control vibration of the cylinder block partition walls.

CRANKSHAFT

The crankshaft is made of nodular cast iron and has six individual throws with five counter weights, it is supported by four main bearings with number three being the thrust bearing. The six separate connecting rod throws pins reduce torque fluctuations while a dynamic damper is used to control torsional vibration of the crankshaft. Rubber lipped seals are used at front and rear. The front seal is retained in

Fig. 2 Engine Oiling

Chrysler JA Cirrus Stratus 1997 Service Manual – Engine

Specifications and Main Features

Frequently Asked Questions

User Manual

ENGINE

GENERAL INFORMATION

FORM-IN-PLACE GASKETS

MOPAR SILICONE RUBBER ADHESIVE SEALANT

MOPAR GASKET MAKER

MOPAR TORQUE CURE GASKET MAKER

GASKET DISASSEMBLY

SURFACE PREPARATION

ENGINE CORE PLUGS

REMOVAL

ENGINE PERFORMANCE

PERFORM CYLINDER COMPRESSION TEST

HONING CYLINDER BORES

MEASURING MAIN BEARING AND CONNECTING ROD BEARING CLEARANCES

PREFERRED METHOD

ALTERNATIVE METHOD

PLASTIGAGE PROCEDURE

CONNECTING ROD BEARING CLEARANCE

REPAIR OF DAMAGED OR WORN THREADS

CHECKING ENGINE OIL LEVEL

API SERVICE GRADE CERTIFIED

SAE VISCOSITY

ENERGY CONSERVING OIL

CONTAINER IDENTIFICATION

ENGINE OIL CHANGE

ENGINE OIL FILTER CHANGE

DIAGNOSIS AND TESTING

GENERAL INFORMATION

INTAKE MANIFOLD LEAKAGE DIAGNOSIS

CYLINDER COMPRESSION PRESSURE TEST

CYLINDER COMBUSTION PRESSURE LEAKAGE TEST

LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS

INSPECTION (ENGINE OIL LEAKS IN GENERAL)

INSPECTION FOR REAR SEAL AREA LEAKS

ENGINE DIAGNOSIS—PERFORMANCE

ENGINE DIAGNOSIS—MECHANICAL

DESCRIPTION AND OPERATION

ENGINE IDENTIFICATION

GENERAL SPECIFICATION

ENGINE LUBRICATION SYSTEM

ENGINE LUBRICATION

PRESSURE LUBRICATION

MAIN/ROD BEARINGS

CAMSHAFT/HYDRAULIC LASH ADJUSTERS

SPLASH LUBRICATION

ENGINE COMPONENTS

DIAGNOSIS AND TESTING

CHECKING ENGINE OIL PRESSURE

SERVICE PROCEDURES

CYLINDER BORE AND PISTON SIZING

CYLINDER BORE AND PISTON

SPECIFICATIONS TABLE

SIZING PISTONS

FITTING PISTON RINGS

FITTING CONNECTING RODS

FITTING CRANKSHAFT BEARINGS

CRANKSHAFT END PLAY

CAMSHAFT END PLAY

REMOVAL AND INSTALLATION

ENGINE MOUNT—RIGHT/ENGINE SUPPORT BRACKET

ENGINE MOUNT—LEFT

ENGINE SUPPORT MODULE (FRONT AND REAR MOUNTS)

REMOVAL

INSTALLATION

ENGINE ASSEMBLY

REMOVAL

INSTALLATION

REMOVAL

INSTALLATION

SPARK PLUG TUBE SEALS

CAMSHAFT END PLAY

CAMSHAFT

REMOVAL

INSTALLATION

ROCKER ARM/HYDRAULIC LASH ADJUSTER

REMOVAL