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ENGINE

C O N T E N T S

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2.2/2.5L ENGINES . . . . . . . . . . . . . . . . . . . . . . . 83.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . . 98STANDARD SERVICE PROCEDURES . . . . . . . . . 1

STANDARD SERVICE PROCEDURES

INDEX

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Crankshaft Sprocket Bolt Access Plug . . . . . . . . . . 2Engine Performance . . . . . . . . . . . . . . . . . . . . . . . 2Form-In-Place Gaskets . . . . . . . . . . . . . . . . . . . . . 1Honing Cylinder Bores . . . . . . . . . . . . . . . . . . . . . 2Hydrostatic Locked Engine . . . . . . . . . . . . . . . . . . 5

Lash Adjuster (Tappet) Noise Diagnosis . . . . . . . . 4Measuring Main Bearing Clearance and ConnectingRod Bearing Clearance . . . . . . . . . . . . . . . . . . . 3

Repair of Damaged or Worn Threads . . . . . . . . . . 4

FORM-IN-PLACE GASKETST h e r e a r e n u m e r ou s p la ce s w h e r e for m -i n -p la ce

g a s k e t s a r e u s e d o n t h e e n g i n e . C a r e m u s t b e t a k e n

when applying form-in-place gaskets to assure ob-

taining th e desired results. Bead size, continuity, an d

location are of great importance. Too thin a bead can

result in leakage while too much can result in spill-

ov er w h ich ca n b r ea k off a n d ob s t r u ct fl u id fe edlines. A continuous bead of the proper width is essen-

tial to obtain a leak-free joint.

T w o t y pe s of for m -i n -p la ce g a sk e t m a t e r i a ls a r e

used in the engine area. Mopar Silicone Rubber Ad-

hesive Sealant and anaerobic gasket materials, each

h a v e d iffe r e n t p r op e r t ie s a n d ca n n o t b e u s e d i n t er -

changeably.

MOPAR SILICONE RUBBER ADHESIVE

SEALANT

Mopar Silicone Rubber Adhesive Sealant or equiv-

alent, n ormally black in color, is a vailable in thr ee

ou n ce t u b e s. M oi st u r e i n t h e a i r ca u s e s t h e M op a r

Silicone Rubber Adhesive Sealant material to cure.

T h is m a t e ria l is n or m a lly u s ed on fle xib le m e t a l

fl a n ge s . I t h a s a s h e lf l ife of o n e y e a r a n d w il l n o t

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 metal-

lic surfaces. I t will not cure if left in the uncovered

tube. It is normally red in color. The anaerobic ma-

terial is for use between two machined surfaces. Do

not used on flexible metal flanges.

GASKET DI SASSEMBLY

Parts assembled with form-in-place gaskets may be

d is a s s em b le d w it h o u t u n u s u a l e ffor t . I n s om e i n -

s t a n c e s , i t m a y b e n e c e s s a r y t o l i g h t l y t a p t h e p a r twith a mallet or other suitable tool to break the seal

b et w e en t h e m a t i n g s u r fa ce s . A fl a t g a s ke t s cr a p e r

m a y a ls o b e lig h tly t a p pe d in t o t h e join t b u t ca r e

m u s t b e t a k e n n o t t o d a m a g e t h e m a t i n g s u r f a c e s .

SURFACE PREPARATION

Scrape clean or wire brush all gasket surfaces re-

moving all loose ma terial . Inspect stamped parts to

assure gasket rails are flat . Flatten rails with a ham-

mer 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 APPLICATI ON

Assembling pa rts using a form-in-place gasket re-

quires care but i ts easier t hen using precut gaskets.

MOPAR Gasket Maker material should be applied

sparingly 1mm(0.040 inch.) diameter or less of seal-

a n t t o on e g a sk et s u r fa ce . B e ce r t ai n t h e m a t e ri al

surrounds each mounting hole. E xcess ma terial can

easily be wiped off. Components should be torqued in

place within 15 minutes. The use of a locating dowel

is recommended during a ssembly t o prevent smear-

ing the material off location.

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T h e M OP AR S il icon e R u b be r Ad h e si ve S e a la n t

gasket material or equivalent should be applied in a

continuous bead approximately 3mm (0.120 inch) in

d ia m e t e r . Al l m ou n t i n g h ol es m u s t b e ci r cl ed . F or

corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 inch.)

d r op i s p l a ce d i n t h e ce n t e r of t h e g a sk e t con t a c t

a r e a . U n c u r e d s e a l a n t m a y b e r e m o v e d w i t h a s h o p

towels. Components should be torqued in place whilet h e s e a l a n t i s s t i l l w e t t o t h e t o u c h ( w i t h i n 1 0 m i n -

utes). The usage of a locating dowel is recommended

during assembly to prevent smearing of material off

location.

CRANKSHAFT SPROCKET BOLT ACCESS PLUGAn Access plug is located in the right inner fender

s h ie ld . R em ove t h e p lu g a n d in s er t p r op er s ize

socket, extension and rachet, when cran kshaft r ota-

tion is necessary.

ENGINE PERFORMANCEIf a loss of perform ance is noticed, ignition timing

should be checked. If ignition t iming is retarded by

9, 18 or 27 indicating 1, 2 or 3 (timing belt or chain)

t e et h m a y h a v e s k i p p ed , t h e n , c a m s h a ft a n d a cce s -

s or y s h a ft t im in g w it h t h e cr a n k s h a ft s h ou ld b e

checked. Refer to E ngine Timing Sprockets and Oil

Seals of the Engine Section.

To provide best vehicle performance and lowest ve-

hicle emissions, i t is most importan t that the tune-up

be done accura tely. Use the specifications l isted on

t h e Ve h icl e E m i s si on C on t r o l I n for m a t i on l a be l

found in the engine compartment.

(1 ) T es t cr a n k in g a m p er a ge d r a w. S ee S t a r t in gMotor Cranking Amperage Draw Electrical Section

of t h i s m a n u a l .

(2) Tighten the intake man ifold bolts to specifica-

tions.

(3) Perform cylinder compr ession test.

(a) Check engine oil level a nd add oil if neces-

sary.

(b) Drive the vehicle until engine reaches normal

operating temperature.

(c) S ele ct a r ou t e fr e e fr om t r a ffic a n d ot h e r

forms of congestion, observe all tra ffic laws, a nd ac-

celerate through the gears several t imes briskly.

CAUTION: Do not overspeed the engine. The higher

engine speed may help clean out valve seat depositswhich can prevent accurate compression readings.

(d ) R em ove a ll s pa r k p lu gs fr om e n gin e . As

spark plugs are being removed, check electrodes for

abnormal firing indicators fouled, hot, oily, etc.

R ecor d cy li n de r n u m b e r of s p a r k p lu g for fu t u r e

reference.

(e) Disconn ect coil wire from distribut or an d s e-

cure to good ground to prevent a spark from start-

ing a fire (Conventional Ignition System). For Direct

Ignition System DIS disconnect the coil connector.

(f) Be sure throttle blade is fully open dur ing the

compression check.

(g) 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 a s #1 cylinder pressure.(h) Repeat St ep G for a ll remaining cylinders.

(i) Compression should not be less than (689kPa)

1 00 p si a n d n ot v a ry m or e t h a n 2 5 p e r ce n t fr om

cylinder to cylinder.

(j) If one or more cylinders have abnormally low

compression pressures, repeat steps 3b through 3h.

(k ) I f t h e s a m e cy li n de r or cy li n de r s r e p ea t a n

abnormally low reading on the second compression

test, it could indicate the existence of a problem in

the cylinder in question.

T h e r e c o m m e n d e d c o m p r e s s i o n p r e s s u r e s a r e

t o b e u s e d o n l y a s a g u i d e t o d i a g n o s in g e n g i n ep r o b le m s . An e n g i n e s h o u l d n o t b e d i s a s s e m b l e d

t o d e t e r m i n e t h e c a u s e o f l o w c o m p r e s s i o n u n -

l e s s s o m e m a l fu n c t i o n i s p r e s e n t .

(4) Clean or replace spark plugs as necessary and

adjust gap as specified in Electrical Group 8. Tighten to

specifications.

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

Ignition System Secondary Circuit Inspection Electri-

cal Section Group 8.

(6) Inspect the primary wire. Test coil output volt-

age, primary and secondary resistance. Replace part s

as necessary. Refer to Ignition System and make nec-

essary adjustment.

(7) Ign ition timing should be set to specificat ions.

(See S pecification Label in engine compa rtm ent).

(8) Test fuel pump for pressu re an d vacuum. Refer to

Fuel System Group 14, Specificat ions.

(9 ) T h e a i r fi lt e r e le m en t s s h ou l d b e r e p la ce d a s

specified in Lubrication and Maintenance, Group 0.

(1 0) I n s p e ct cr a n k ca s e v en t i la t i on s ys t e m a s ou t

lined in Lubrication and Maintenance, Group 0. For

emission controls see Emission Controls Group 25 for

service procedures.

(11) Inspect and adjust accessory belt drives refer-

ring to Accessory Belt Drive in Cooling System, Group

7 for proper adjustments.

(12) Road test vehicle as a final test.

HONING CYLINDER BORESBefore honing, stuff plenty of clean shop towels

under the bores, over the crankshaft to keep abrasive

materials from entering crankcase a rea.

(1) Used carefully, t he 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

a n d ou t -of-r ou n d a s well a s r em ovin g ligh t

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scuffing, scoring or scra tches. Usu ally a few st rokes

will clean up a bore a nd maintain the required l imits.

(2 ) D e gl a zi n g of t h e cy li n de r w a ll s m a y b e d on e

using a cylinder surfacing hone, Tool C-3501, equipped

with 280 grit stones (C-3501-3810) if the cylinder bore

is straight and round. 20-60 strokes depending on th e

bore condition will be sufficient to provide a satisfac-

t or y s u r fa ce . I n s p ect cy li n de r w a ll s a ft e r e a ch 2 0strokes. Using a light honing oil available from major

oil distributors. D o n o t u s e e n g i n e o r t r a n s m i s s i o n

o i l , m in e r a l s p i r i t s o r k e r o s e n e .

(3) Honing should be done by moving the hone up

a n d d ow n fa s t e n ou g h t o g e t a cr os s -h a t c h p a t t e r n .

Wh e n h on e m a r k s i n t e r s e c t a t 5 0-6 0 d e gr e e s, t h e

cross hatch angle is most satisfactory for proper seat-

ing of rings (Fig. 1).

(4) A controlled h one motor speed between 200-300

R P M i s n e ce ss a r y t o ob t a in t h e p r op e r cr os s -h a t c h

angle. The num ber of up a nd 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, i t is necessary that the block be

cleaned again to remove all traces of abrasive.

CAUTION: Be sure all abrasive are removed fromengine 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 CLEARANCE ANDCONNECTING ROD BEARING CLEARANCE

PLASTIGAGE METHOD

Engine crankshaft bearing clearances can be deter-

mined by use of Plastigage or equivalent. The follow-

i n g is t h e r e com m en d ed p r oce du r e for t h e u s e of

Plastigage:(1) Remove oil fi lm from surface to be checked.

Plastigage is soluble in oil.

(2) The total clearance of the m a i n b e a r i n g s ca n

on l y b e d e t er m i n ed b y r e m ov in g t h e w ei gh t of t h e

cr a n k s h a f t . T h i s ca n b e a ccom p li sh e d b y e it h e r of

two methods:

PREFERRED METHOD S h i m m i n g t h e b e a r -

ings adjacent to the bearing to be checked in order to

r e m ov e t h e cl ea r a n c e b et w ee n u p p er b ea r i n g s h e ll

a n d t h e cr a n k s h a ft . T h is ca n b e a ccom p li sh e d b y

placing a minimum of 0.254mm (.010 inch) sh im (e.

g . ca r d b oa r d , m a t c h book cov er , e t c.) b et w ee n t h e

b ea r in g s h ell a n d t h e b ea r in g ca p on t h e a d ja ce n t

b ea r in gs a n d s n u gg in g b olt s t o 1 4-2 0 Nm (10-15

ft.lb.)

When checking #1 main brg shim #2 main brg

When checking #2 main brg shim #1 & 3 main brg



When checking #5 main brg shim #4 main brg

Fig. 2 Plastigage Placed in Lower Shell

Fig. 3 Clearance Measurement

Fig. 1 Cylinder Bore Cross-Hatch Pattern

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R E MO VE AL L S H IMS B E F OR E R E AS S E M-

BLING ENGINE

ALTERN ATIVE METHOD With the weight of

t h e c r a n k s h a f t b e i n g s u p p o r t e d b y a j a c k u n d e r t h e

counterweight adjacent to the bearing being checked.

(3 ) P l a ce a p ie ce of P l a s t ig a ge a cr os s t h e e n t ir e

w id t h of t h e b ea r i n g s h e l l i n t h e ca p a p p r ox im a t e ly

6.35 mm (1/4 inch) off center and away from the oilh ol es (F i g. 2 ). (I n a d d it i on , s u s p ect a r e a s ca n b e

checked by placing the Plastigage in the suspect area).

Tor q u e t h e b ea r i n g ca p b ol t s of t h e b ea r i n g b ei n g

checked to t he proper specifications.

(4) Remove the bearing cap and compare the width

of the flat tened Plast igage (Fig. 3) with t he m etric scale

provided on th e package. Locate th e band closest t o the

same width. This ban d sh ows th e am ount of clearan ce

in t housan dth s of a m illimeter. Differences in r eadings

between the ends indicate the amount of taper present.

Record all readings taken. Refer to Engine Specifica-

tions. P l a s t i c - G a g e g e n e r a l l y i s a c c o m p a n i e d b yt w o s c a l e s . O n e s c a l e i s i n i n c h e s , t h e o t h e r i s a

m e t r i c s c a l e .

(5) Plastigage is available in a variety of clearance

ranges. The 0.025-0.076mm (.001-.003 inch) is usually

t h e m os t a p p r op r ia t e for ch e ck in g e n gi n e b ea r i n g

proper specifications.

CONNECTING ROD BEARING CLEARANCE

Engine crankshaft bearing clearances can be deter-

mined by use of Plastigage or equivalent. The following

is the recommended procedure for the use of Plasti-

gage:

(1) Rotate the crankshaft until the connecting rod to

be checked is at the bottom of its stroke.

(2) Remove oil fi lm from surface to be checked.

Plastigage is soluble in oil.

(3 ) P l a ce a p ie ce of P l a s t ig a ge a cr os s t h e e n t ir e

width of the bearing shell in the bearing cap approxi-

mately 6.35 mm (1/4 inch.) off center and away from

the oil hole (Fig. 2). In addition, suspect areas can be

checked by placing plastigage in the suspect area.

(4) Before assembling the rod cap with Plast igage in

p l a c e , t h e c r a n k s h a f t m u s t b e r o t a t e d u n t i l t h e c o n -

necting being checked starts moving toward the top of

the engine. Only then should the cap be assembled andtorqued to specificat ions. D o n o t r o ta t e t h e c r an k -

s h a f t w h i l e a s s e m b l i n g t h e c a p o r t h e P l a s t i g a g e

m a y b e s m e a r e d , g i v in g i n a c c u r a t e r e s u l ts .

(5) Remove the bearing cap and compare the width

of t h e fl a t t en e d P l a s t ig a ge (F i g. 3 ) w i t h t h e m e t r ic

scale provided on t he package. Locat e t he band closest

t o t h e s a me w id t h. T his b an d s how s t h e a m ou n t

of clearance in thousandths of a millimeter. Differences

i n r e a d in g s b e t w ee n t h e e n d s i n d ica t e t h e a m ou n t

of t a per p res en t . Recor d a ll r ea din gs t a ken .

Refer to Engine Specifications. P l a s t i g a g e g e ne r a l l y

i s a c c o m pa n ie d b y t w o s c al e s. O n e s c al e i s i n

i n c h e s , t h e o t h e r i s a m e t r ic s c a l e .

(6) Plastigage is available in a variety of clearance

ranges. The 0.025-0.076mm (.001-.003 inch) is usually

t h e m os t a p p r op r ia t e for ch e ck i n g e n gi n e b ea r i n g

proper specifications.

LASH ADJUSTER (TAPPET) NOISE DIAGNOSISA tappet-like n oise ma y be produced from severalitems. Ch eck the following items.

(1) Engine oil level t oo h igh or too low. This m ay

cause aerated oil to enter the adjusters and cause them

to be spongy.

(2) Insufficient running time after rebuilding cylin-

d er h e a d. L ow s p ee d r u n n i n g u p t o 1 h ou r m a y b e

required.

During t his time, tur n engine off and let set for a few

minutes before restarting. Repeat this several t imes

after engine has reached normal operating tempera-

t u r e .

(3) Low oil pressur e.

(4) The oil restrictor pressed into the vertical oil

passage to the cylinder head of Balance Shaft Engines

Only is plugged with debris.

(5) Air ingested into oil due to broken or cracked oil

pump pick up.

(6) Worn valve guides.

(7) Rocker arm ea rs conta cting valve spring retainer

(2.2/2.5L engines).

(8) Rocker arm loose, adjuster or tappet stuck or at

ma ximu m extension an d still leaves lash in th e system.

(9) Faulty lash adjuster or tappet.

(a) Check for sponginess while sti ll installed in

engine. Depress pa rt of rocker arm just over a djuster

or pushrod . Normal adjusters should feel very firm.

Spongy adjusters can be depressed to the bottomed

position easily.

(b) Remove suspected lash adjuster or tappet, pry

off retainer cap or snap ring and disassemble. D o

n o t r e u s e r e t a i n e r c a p s . Do not interchan ge parts

and make sure that care and cleanliness is exercised

in th e ha ndling of parts.

(c) Clean out dirt an d varnish with solvent.

(d) Reassemble with engine oil.

(e) Ch eck for sponginess.(f) If still spongy, replace with new adjuster.

REPAIR OF DAMAGED OR WORN THREADSDamaged or worn threads (including aluminum head

spark plug threads) can be repaired. Essentially, this

r e pa ir con s is t s of d r illin g ou t w or n or d a m a ge d

threads, tapping the hole with a special Heli-Coil (or

e qu iv a le n t ) T a p, a n d in s t a lli n g a n i n se r t in t o t h e

tapped hole. This brings the hole back to i ts original

thr ead size.

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CAUTION: Be sure that the tapped holes maintainthe original centerline.

H e li -C oi l t ool s a n d i n se r t s a r e r e a d il y a v a il a bl e

from automotive parts jobbers.

HYDROSTATIC LOCKED ENGINEW h en a n e n gi n e i s s u s p ect e d t o b e h y d r os t a t i cl y

locked, regardless of what caused the problem, these

steps should be used.

CAUTION: Do Not Use Starter Motor To Rotate En-gine, severe damage may occur.

(1 ) I n s p ect a i r cl ea n e r , i n du ct i on s ys t e m a n d i n -

t a k e m a n i fol d t o i n s u r e s ys t e m i s d r y a n d cl ea r of

foreign material.

(2) Remove negative battery cable.

(3 ) P la ce a s h op t ow el a r ou n d t h e s pa r k p lu gs

w h en r e m ov in g t h e m fr om t h e e n gin e . T h is w il l

catch any fluid that may possibly be in the cylinder

under pressure.

(4 ) Wi t h a l l s p a r k p lu g s r e m ov ed , r ot a t e e n gi n e

crankshaft using a breaker bar and socket.

(5) Iden tify th e fluid in the cylinder(s) (i.e., cool-

ant, fuel, oil or other).

(6) Make sure all f luid has been removed from the

cylinders. Inspect en gine for dama ge (i.e., Conn ecting

Rods, Pistons, Valves etc.)

(7 ) R e pa i r e n gi n e or com p on e n t s a s n e ce s sa r y t o

prevent this problem from occurring again.

CAUTION: Squirt approximately 1 teaspoon of oil

into cylinders, rotate engine to lubricate the cylin-

der 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.

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ENGINE DIAGNOSISPERFORMANCE

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ENGINE DIAGNOSISMECHANICAL

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2 . 2 / 2 . 5 L E N G I N E S

INDEX

page page

Balance Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Camshaft and Crankshaft Timing Procedure . . . . 34Camshaft, Crankshaft and Intermediate Shafts

Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . 20Camshafts Service . . . . . . . . . . . . . . . . . . . . . . . 36Checking Engine Oil Pressure . . . . . . . . . . . . . . . 60Crankshaft Oil Seals Service . . . . . . . . . . . . . . . . 42Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . 43Crankshaft, Intermediate and Balance Shaft

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Cylinder Block, Piston and Connecting Rod

Assembly Service . . . . . . . . . . . . . . . . . . . . . . . 49Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Cylinder Head and Valve Assembly

ServiceExcept Turbo III . . . . . . . . . . . . . . . . . 22Cylinder Head and Valve Assembly

ServiceTurbo III . . . . . . . . . . . . . . . . . . . . . . 31Cylinder Head ComponentsIn-Vehicle Service . 23Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 13

Engine Core Plugs . . . . . . . . . . . . . . . . . . . . . . . 55

Engine Lubrication System . . . . . . . . . . . . . . . . . 56Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . 12Engine Specifications . . . . . . . . . . . . . . . . . . . . . . 62General Information . . . . . . . . . . . . . . . . . . . . . . . . 8Intermediate Shaft Service . . . . . . . . . . . . . . . . . . 47Lash Adjuster (Tappet) Noise . . . . . . . . . . . . . . . 37Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . 58Solid Mount Compressor Bracket Service . . . . . . 14Timing System and Seals Service

Except Turbo III . . . . . . . . . . . . . . . . . . . . . . . . 18Valve Components ReplaceCylinder Head

Not Removed . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Valve ServiceCylinder Head Removed . . . . . . . 27Valve Springs and Valve Stem Seals . . . . . . . . . 38

GENERAL INFORMATION

ENGINE IDENTIFICATION NUMBER OR CODE

The engine identification number is located on the

r e a r of t h e cy li n de r b lock ju s t b el ow t h e cy li n de r

head (Fig. 1).

METHANOL FUEL COMPATIBILITY IDEN-

TIFICATION

Beginning this model year, Chrysler began produc-

ing AA-Body vehicles designed to operate on a mix-

ture of gasoline and methanol. These automobiles are

referred to as Flexible Fuel vehicles.

2.2/2.5L ENGINE SPECIFICATION

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Flexible fuel vehicles can operate on a mixture of

up to 85 percent methanol, 15 percent unleaded gas-

oline. These vehicles also operat e on mixtures con-

taining a lower percentage of methanol or just pure

unleaded gasoline.

Engine components which are required for safe op-

eration using fuel conta ining methan ol alcohol are

identified by a standar d green color and/or display

the statement methanol compatible imprinted on the

component. To ensure continued safe operation, thesecomponents must be serviced only with genuine MO-

PAR replacement parts.

Methanol compatible parts for the 2.5L FFV (Flex-

ible Fuel Vehicle) engine include, but are not limited

to; the valve stem oil seals, a ll piston r ings, t he oil

fill cap, the fuel injectors, fuel rail, fuel pressure reg-

ulator, hoses and the vacuum control harness hose.

BLOCK: All four cylinder cast iron blocks have

cast-in recesses in the bottom of each cylinder bore to

provide connecting rod cleara nce; especially needed

for 2.5L engines. The bores are also siamese to min-

i m iz e e n gi n e l en g t h . A cool a n t p a s s a ge i s d r il le d

cross-ways t hrough the siamese section to enh ance

b et w ee n t h e b or e cool in g on s om e e n gi n e t y pe s . A

partial open deck is used for cooling and weight re-

duction with oil fi lter, water pump, and distributor

mounting bosses molded into the front (radiator side)

of the block. Nominal wall thickness is 4.5 mm. Five

main bearing bulkheads and a block skirt extending

3 m m b elow t h e cr a n k s h a ft ce n t er lin e a d d t o t h e

blocks high rigidity with light weight.

CRANKSHAFT: A nodular cast iron crankshaft is

u s e d i n T BI e n gi n es . A f or g ed s t e el cr a n k s h a f t i s

u s ed i n t h e T u r bo I II e n gin e . A ll e n gin e s h a v e 5

m a in b ea r in gs , w it h n u m b er 3 fla n ge d t o con t r ol

t h r u s t . T h e 6 0 m m d i a m e t e r m a i n a n d 5 0 m m d i a m -

eter crank pin journals (all) have undercut radiuses

fil lets that are deep rolled for added strength. To op-

t i m iz e b ea r i n g l oa d in g 4 cou n t e r w ei gh t s a r e u s e d.

Hydrodynamic seals (installed in diecast aluminum

retainers) provide end sealing, where the crankshaft

exits the block. Anaerobic gasket material is used forr e t a in e r -t o-b lock s e a li n g. N o v ib r a t ion d a m p e r i s

u s e d. A s in t e r e d i r on (T BI e n gi n e a n d s t e el b il le t

Turbo III engines) t iming belt sprocket is m ount ed

on the crank shaft nose. This sprocket provides mo-

tive power; via t iming belt to the camsha ft and inter-

m e dia t e s h a ft s pr ock et s (a ls o s in t e r ed ir on (T BI

engine and steel billet Turbo III engines) providing

timed valve, distributor, and oil pump actuation.

PISTONS: S om e C h r ys le r p is t on s h a v e ca s t -i n

steel struts at the pin bosses for autothermic control.

Al l 2 .2L a n d 2 .5 L p is t on t op s h a v e cu t s t o p r ov id e

valve clearance. Some pistons are dished to providevarious compression ratios. St andar d 2.2L a nd 2.5L

engines are designed for 9.5:1 and 8.9:1 compression

ratios respectively. The 2.5L piston is dished and is a

l ig h t we ig h t d e si gn t o e n h a n ce e n gi n e s m oot h n e s s .

T h e 2 .2 L t u r b o I I I u s e s d is h e d p is t on s p r ov id in g a

8.3:1 compression ratio. All standa rd 2.2/2.5L and

2 .5 L F F V e n gi n es u s e p r e ss e d-i n p is t on p in s t o a t -

tach forged steel connecting rods, 2.2L turbo III en-

gine uses a full f loating piston pin and connecting

rod assembly.

P I ST ON S R I N GS: T h e 2 .2 /2 .5 L e n gi n es s h a r e

common piston rings throughout, including molybde-

num filled top ring for reliable compression sealingand a tapered faced intermediate ring for additional

cylinder pressure contr ol. The 2.5L FFV engine fea-

t u r e a l l ch r o m e r i n g s f or e n h a n ce d l on g t e r m d u r a -

bility und er multi-fueled conditions.

CYLINDER HEAD: The cylinder head is cast a lu-

m i n u m w it h i n -l in e v a lv es . T h e 2 .2 /2 .5 L a n d 2 .5 L

F F V v a l ve s a r e a r r a n g e d w i t h a l t er n a t i n g e x h a u s t

and intake. The intake and exhaust ports are located

i n t h e r e a r w a r d , f a c i n g s i d e o f t h e h e a d . T h e T u r b o

III valves are arranged in two inline banks, with the

p or t s of t h e b a n k of t w o i n t a k e v a lv es p e r cy li n de r

facing t oward the radiator side of engine and ports of

the bank of two exhaust valve per cylinder facing to-

ward the dash panel. The intake ports feed fast-burn

design combustion chambers (2.2/2.5L and 2.5L FFV

only) with the spark plug located close to the center

l in e of t h e com b u s t ion ch a m b e r for op t im u m e ffi -

ciency. An integral oil gallery within the cylinder

h e a d s u pp lie s oil t o t h e h yd r a u lic la s h a d ju s t er s ,

camshaft, and valve mechanisms.

CAMSHAFT: The nodular iron camshaft has five

bearing journals (2.2/2.5L and 2.5L FFV). The Turbo

I I I e m p loy s d u a l ca m s h a ft s t h a t h a v e n i n e b ea r i n g

jou r n a ls . F la n ge s a t t h e r ea r jou r n a l con t r ol ca m -

Fig. 1 Engine Identification

2.2/2.5L ENGINE 9 - 9

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shaft end play. A sintered iron (TBI engine and steel

b ill et T u r bo I II e n gi ne s) t im in g b elt s pr ock e t is

m ou n t e d on t h e ca m n os e , a n d a h y d r od yn a m i c oi l

s e a l i s u s e d f or oi l con t r ol a t t h e fr on t of t h e ca m -

shaft.

ACCESSORY SHAFT: The iron accessory shaft

h a s t w o b ea r i n g j ou r n a l s a n d i s h o u s ed i n t h e for -

ward facing side of the block. A hydrodynamic seal,in s t a lle d in a n a lu m in u m h ou s in g a t t a ch e d t o t h e

block, provides retention, shaft thr ust, and oil con-

trol. The accessory shaft is driven by the t iming belt

through a sintered iron (TBI engine and steel bil let

Turbo III engines) sprocket mounted on the nose of

t h e a cce ss or y s h a ft . T h e a cce ss or y s h a ft in t u r n

drives th e oil pump and distributor on 2.2/2.5L an d

2 .5 L F F V a n d t h e oi l p u m p on l y on T u r b o I II .

VALVES: T h e v a lv es a r e a ct u a t e d b y r o ll er ca m

followers which pivot on stationary hydraulic lash

adjusters. The valve train with 40.6 mm (1.60 inch)

diameter intake valves and 35.4 mm (1.39 inch) di-

a m e t e r e xh a u s t v a lv es e m p loy v it on r u b b er v a lv es t em s ea ls e xce pt 2 .5 L F F v . t h e 2 .5 L F F V v a lve

s t em s ea ls a r e m a d e of s p ecia l r u b be r com p ou n d

w h ich r e s is t t h e d e t er i or a t i n g e ffe ct s of m e t h a n ol

fu e l b y-p r od u ct s t h a t e n t e r t h e oi l d u r i n g com b u s -

t i on . Va l ve s p r in g s , s p r i n g r e t a i n er s , a n d l ock s a r e

con v en t i on a l . F or T u r b o I I I e n gi n es t h e v a lv es a r e

actuated by roller t ipped rocker arms with hydraulic

lash a djusters which pivot on a shaft . The valve train

with 33.88 mm (1.33 in.) diameter intake valves are

arranged in l ine opposite of the 29.26 mm (1.15 in.)

diameter exhau st valves employ locking valve stem

seals. Valve springs, spring retainers, and locks are

not interchangeable with other engines.BALANCE SHAFTS: 2 .2 T u r b o I I I a n d 2 .5 L e n -

gines are equipped with two count er rotating balance

s h a ft s in s t a lle d in a ca r r ie r a t t a ch e d t o t h e low er

cr a n k ca s e. T h e s h a ft s a r e in t e r con n e ct t h r ou gh

gears. These gears are driven by a short chain from

t h e cr a n k s h a ft , t o r ot a t e a t t w o t i m es cr a n k s h aft

speed. This counterbalances certain engine recipro-

cating forces.

INTAKE MANIFOLDS: All intake manifolds are

a l u m in u m ca s t i n gs , a t t a c h ed t o t h e cy li n de r h e a d

with eight bolts. N.A. engines use a four branch de-

sign. This long branch fan design enhances low and

midspeed torque. It also features an integrally cast

water crossover passage to warm incoming fuel/air

mixture, plus an EGR mounting boss and PCV inlet.

The Turbo III engine intake manifold is a log type

with tuned runners. The manifold is machined to ac-

cept fuel injectors near the ports of each cylinder.

EXHAUST MANIFOLDS: The exhaust manifolds

a r e m a d e o f n o d u l a r c a s t i r o n f o r s t r e n g t h a n d h i g h

temperatures. All naturally aspirated (N.A.) and tur-

bocharged engines exit exhaust gasses through a ma-

chined, a rticulated joint connection to the exhaust

p ip e . 2 .2 /2 .5 L a n d 2 .5 L F F V m a n i fol ds i n t er m e s h

with the intake manifold at the cylinder head.

N.A. engines use a four branch design with cylin-

ders one and four joined and cylinder two and three

join ed t o exit a t t h e ou t let .The Turbo III engine exhau st manifold a lso carries

the turbocharger. This m anifold h as a modified log

t y pe col le ct or w it h e xh a u s t g a s se s d ir e ct e d t o a n d

through the turbocharger to exit the conical (articu-

lated joint) outlet machined into the turbocharger ex-

haust elbow.

ENGINE LUBRICATION: R e f e r t o G r o u p 0 L u -

brication and Maintenance for recommended oil to be

u s e d i n v a r iou s e n gi n e a p p li ca t i on . S ys t e m i s fu l l

flow filtrat ion, pressure feed type. The oil pum p is

mounted within the crankcase and driven by the ac-

cessory shaft . Pressurized oil is then routed throughthe main oil gallery, running the length of the cylin-

der block, supplying main and rod bearings with fur-

ther routing (for 2.2L turbo III and 2.5L engines) to

the lower balance shaft assemblies. Pistons are lubri-

cated from directed holes in the connecting rod as-

s em blie s. C am s ha ft a n d va lve m ech a n is ms a r e

lubricated from a full-length cylinder h ead oil gallery

supplied from the crankcase main oil gallery.

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Fig. 2 Engines

2.2/2.5L ENGINE 9 - 11

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ENGINE MOUNTS

REMOVAL AND INSTALLATION

RIGHT SIDE MOUNT(1) Remove the right engine m ount insulator ver-

tical fasteners from frame rail .

(2 ) R e m ov e t h e l oa d on t h e e n gi n e m o t or m ou n t s

by carefully supporting the engine and transmission

assembly with a floor jack.

(3) Remove the thru bolt from the insulator assem-

bly. Remove insulator.

(4) Reverse removal procedure for installation. Re-

fer to (Fig. 3) for bolt tightening specificat ions.

(5 ) E n g in e m ou n t a d ju s t m en t , R efe r t o E n gin e

Mount Insulator Adjustment of this section.

FRONT MOUNT(1) Support the engine and transmission assembly

with a floor jack so i t will not rotate.

(2 ) R em ov e t h e t h r u b ol t fr om t h e i n su l a t or a n d

front crossmember mounting bra cket.

(3 ) R em ov e t h e fr on t e n gin e m ou n t b r a ck e t t o

front crossmember screws and nuts. Remove the in-

sulator assembly.

(4) Reverse removal procedure for installation. Re-

fer to (Fig. 3) for bolt tightening specificat ions.

(5 ) E n g in e m ou n t a d ju s t m en t , R efe r t o E n gin e


LEFT SIDE MOUNT

(1 ) R a is e v eh i cl e on h oi st a n d r e m ov e l eft fr on t

wheel.

(2) Remove inter splash shield.

(3 ) S u p p or t t h e t r a n s m i ss ion w it h a t r a n s m i s si on

ja ck.

(4) Remove the insulator thr u bolt from the m ount.

(5 ) R em ov e t h e t r a n s m i s si on m ou n t fa s t e n er s a n d

remove mount.

(6) Reverse removal procedure for installation. En-

s ur e t h at t h e s lid e t u be is s ea t ed in t o t h e r a il

bracket guides. Refer to (Fig. 3) for bolt t ightening

specifications.

(7 ) E n g in e m ou n t a d ju s t m en t , R efe r t o E n gi n e


ENGINE MOUNT RUBBER INSULATORS

I n s u la t or l oca t i on on fr a m e r a i l (r i gh t s id e ) a n d

transmission bracket (left side) are adjustable to al-

l ow r i gh t /l eft d r iv e t r a i n a d ju s t m e n t i n r e la t i on t o

drive shaft assembly length.

Check and reposition right engine mount insulator

(left engine mount insulator is floating type and will

adjust automatically (Fig. 4). Adjust drive train posi-

tion, if required, for the following conditions:

Fig. 3 Engine Mounting

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Drive shaft distress: See Driveshafts in Suspension,

Group 2.

Any front end st ructural damage (after repair).

Insulator replacement.

ENGINE MOUNT INSULATOR ADJUSTMENT

(1) Remove the load on the engine motor mounts by

carefully supporting the engine and transmission as-sembly with a floor jack.

(2) Loosen the right engine mount insulator vertical

fasteners, and the front engine mount bracket to front

crossmember screws a nd nuts.

Le ft e n g in e m o u n t i n su l at or i s s le e v e d o v e r

s h a ft a n d l o n g s u p p o r t b o l t t o p r ov i d e l a t e ra l

m o v em e n t a d ju s tm e n t w i th e n g in e w e i g ht r e -

m o v e d o r n o t .

(3) Pr y the engine right or left as r equired to achieve

t h e p r op e r d r iv e s h a ft a s s em b ly l en g t h . S e e D r i ve

Shaft in Suspension Group 2 for driveshaft identifica-

tion and related assembly length measu ring.

(4) Tighten right engine mount insulator vertical

bolts t o 68 Nm (50 ft. lbs.). Then tighten front engine

m o u n t s c r e w s a n d n u t s t o 5 4 Nm (4 0 ft . l bs .) a n d

center left engine mount insulator.

(5) Recheck drive shaft length.

ENGINE ASSEMBLY

REMOVAL(1) Disconn ect bat ter y.

(2) Scribe hood hinge outline on hood and remove

hood.

(3) Drain cooling system.

(4) Remove hoses from radiator and engine.

(5) Remove radiator and fan assembly.

(6) Remove air cleaner and hoses.

(7) Remove air conditioning compressor mount ing

bolts and set compressor aside, if equipped.

(8 ) R e m ov e p ow er s t e er i n g p u m p m ou n t i n g b ol t s

and set pump aside

(9) Rem ove oil filter.

(10) Disconn ect fuel line, hea ter hose an d a cceler-

ator cable.

(11) Disconn ect all electrical conn ections a nd ha r-

nesses at throttle body and engine.

(12) Ma nua l T r a ns m i s s i o n

(a) Disconn ect clutch cable.

(b) Remove t ra nsmission case lower cover.(c) Disconnect exhaust pipe at manifold.

(d) Disconnect starter and lay aside.

(e) Install transmission holding fixture.

(13) A ut o m a t i c T r a ns m i s s i o n

(a) Disconnect exhaust pipe at manifold.

(b) Disconnect starter and lay aside.

(c) Remove t ran smission case lower cover.

(d) Mark flex plate to torque converter.

(e) Remove screws holding torque converter to

flex plate.

(14) Attach C clamp on front bottom of torque con-

verter housing to prevent torque converter from com-ing out.

(15) Install transmission holding fixture.

(16) Remove right inner splash shield (Fig. 5).

(17) Remove ground strap.

(18) To l o w e r e ngin e s ep a ra t e r igh t e ngin e

bracket from yoke bracket To r a i s e engine r emove

l on g b ol t t h r o u gh y ok e a n d i n su l a t or . I F I N S U LA-

T OR T O R A IL S C RE W S AR E T O B E R E MO VE D ,

MARK INSULATOR POSITION ON SIDE RAIL TO

INSURE EXACT INSTALLATION (Fig. 4).

(19) Remove tran smission case to cylinder block

mounting screws.

Fig. 5 Right Inner Splash Shield

Fig. 4 Left Insulator Movement

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CAUTION: Make sure clutch cable has been discon-

nected.

(20) Remove front engine mount screw and nut.

(21) Remove manual transmission damper.

(22) Remove left insulat or th rough bolt from in side

w h ee lh ou s e or in s u la t or b r a ck et t o t r a n s m is si on

screws.(23) Remove engine from vehicle.

INSTALLATION

(1 ) I n st a l l h o is t t o t h e e n gi n e a n d l ow er e n gi n e

into the engine compartment.

S E E : E N G I N E M OU N T R U BB E R I N S U LAT O RS ,

THIS GROUP.

(2 ) Al ig n e n gi n e m ou n t s a n d i n s t a ll b u t d o n o t

t i g h t e n until a ll mounting bolts have been installed.

(3 ) I n s t a ll t r a n s m i ss ion ca s e t o cy li n de r b lock

m ou n t in g s cr e ws . T igh t e n t o 9 5 Nm (7 0 ft . lb s.)

torque.

(4) Remove engine h oist and tran smission holding

fixture.

(5) Install ground strap.

(6) Install r ight inner splash shield.

(7) Connect st arter. See Electrical Group 8 for in-

stallation.

(8) Connect exhaust system. See Exhaust Systems

Group 11 for installation.

(9) Ma n u a l T ra n s m i s s i o n : Install tran smission

case lower cover.

Au t o m a t i c T ra n s m i s s i o n : Remove C clamp from

torque converter housing. Align flexplate to torque

converter and install mounting screws. Tighten to 75Nm (55 ft. lbs.) torque.

(10) Ma nua l T r a ns m i s s i o n: Conn ect clut ch cable.

See Clutch Group 6.

(11) Install power steering pump. Refer to Cooling

System Group 7, Accessory Drive Section for belt

tension adjustment.

(12) Connect fuel line, heater hose, and accelerator

cable.

(1 3) C on n e ct a l l e le ct r i ca l con n e ct i on s a n d h a r -

nesses at throttle body and engine.

(14) Install oil f i lter. Fill engine cran kcase with

proper oil to correct level.

(1 5) I n st a ll a ir con d it ion in g com p res sor (if

equipped). See H eater and Air Conditioning, Group

24 for installation.

(16) Install air cleaner and hoses.

(17) Install radiator and shroud assembly . Install

ra diator hoses. Fill cooling s ystem. See Cooling Sys-

tem Group 7 for filling procedure.

(18) Install hood.

(19) Connect battery.

( 2 0 ) S t a r t e n g i n e a n d r u n u n t i l o p e r a t i n g t e m p e r -

a t u r e i s r e a ch e d .

(21) Adjust transmission linkage, if necessary.

SOLID MOUNT COMPRESSOR BRACKET SERVICEWh e n s er vice p r oce du r e s r e qu ir e s olid m ou n t

bracket removal and installation for example: cylin-

d e r h e a d r e m ov a l, e t c. , i t i s i m p or t a n t t h a t b r a ck e t

fasteners numbered 1 through 7 (Fig. 4) be removed

a n d i n s t a ll ed i n s e qu e n ce , a s i n st r u c t ed i n R em ov e

a n d I n s t a ll .

ACCESSORIES REMOVAL

(1) Remove (an d install/adjust) belts,see Accessory

Drive Belts in Cooling System,Group 7.

(2) Remove air conditioning compressor (in vehicle

with l ines and set aside) (Fig. 6).

(3) Remove generator pivot bolt and remove gener-

ator (in vehicle: turn wiring side up and disconnect,

then rotate generator, pulley end towards engine and

remove).

(4) Remove a ir conditioner compressor belt idler.

SOLID MOUNT BRACKETREMOVAL (FIG. 4)

(1 ) R em ov e r i gh t e n gi n e m ou n t y ok e s cr e w (s e e

Engine Remove Fig. 3) securing engine mount sup-

p or t s t r u t t o e n g in e m ou n t b r a ck e t .

(2) Remove five side mounting bolts #1, #4 , #5,

#6, and #7 (Fig. 4).

(3 ) R e m ov e fr on t m ou n t i n g n u t , # 2, a n d r e m ov e

front bolt #3*.

(4 ) R e m ov e f r on t m ou n t i n g b ol t a n d s t r u t , r ot a t e

s oli d m ou n t b r a ck et a w a y fr om e n gin e a n d s lid e

b r a ck et on s t u d u n t i l # 2 n u t m ou n t in g s t u d u n t i l

free. Remove spacer from stud.

SOLID MOUNT BRACKETINSTALLATION(1 ) P u t s p a ce r on t o s t u d , t h e n i n st a l l b r a ck e t on

front (#2 nut) mounting stud and slide bracket over

timing belt cover into position.

(2 ) L oos e n a s s em b ly b r a ck e t t o e n gi n e fa s t e n er s

(numbered #1 through #7 in Fig. 6).

(3)

CAUTION: Fasteners MUST BE TIGHTENED IN SE-

QUENCE and to specified torque as follows :

First Bolt #1 to 3.3 Nm (30 in. lbs.)

Second Nut #2 and Bolt #3 to 54 Nm (40 ft. lbs.).

Third Bolts #1 (second tightening) #4 and #5 to

54 Nm (40 ft. lbs.).

F o u r t h B o l t s # 6 a n d # 7 t o 5 4 Nm (40 ft. lbs.).

(4) Install generator and compressor. Tighten com-

p r es sor m ou n t in g b r a ck et b olt s t o 5 4 Nm (4 0 f t .

lbs.).

SOLID MOUN T COMPRESSOR BRACKET

SERVICETURBO III ENGINE

REMOVAL

(1) Disconnect negative battery cable

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(2) Remove Accessory Dr ive Belt. Refer to Cooling

System Group 7 for procedure.

(3) Remove a ccessory dr ive belt idler pulley (Fig.

7).

(4 ) R em ov e a i r con d it i on i n g com p r e ss or a n d s e t

aside (Fig. 8).

(5 ) R em ov e g en e r a t or a t t a c h in g b ol t s s e t a s id e

(Fig. 8).

(6) Remove t iming belt covers. Refer to pr ocedure

outlined in this section.

(7) Remove right engine mount yoke bolt. Remove

t h e fa s t e n er s h ol di n g t h e s t r u t i n t o p l a ce . R e m ov e

strut from engine (Fig. 9).

(8 ) R em ov e a cce ss or y d r ive b elt i dle r p u lle y

bracket (Fig. 9).

(9 ) R em ov e t i m in g b el t . R efe r t o p r oce d u r e ou t -

lined in this section.

(10) Remove 2 bolts holding solid m oun t compres-

sor into place, Rotate bracket off engine (Fig. 7).

INSTALLATION

(1) Loosely assemble the bracket to engine with #1

and #2 bolts t ighten to 3.3 Nm (30 in. lbs.) (Fig. 8).

(2) Install t iming belt . Refer to procedure outlined

in this section. Install t iming belt covers. Refer to

procedure outlined in this section.

( 3 ) I n s t a l l s t r u t o n s t u d . T i g h t e n n u t # 3 a n d b o l t

#4, torque to 54 Nm (40 ft. lbs.) (Fig. 9). Loosen #1

and #2 bolts, then torque to 54 Nm (40 ft. lbs.) (Fig.

1 0).In s t a l l y ok e b ol t a n d t or q u e t o 1 02 Nm (7 5 f t .

lbs.).

(4 ) I n st a l l a cce s sor y d r iv e b el t i dl er p u ll ey a n d

bracket (Fig. 8).

(5 ) I n st a l l a cce s sor y d r iv e b el t t e n s ion e r p u ll ey

(Fig. 7).

(6) Install generator (Fig. 8).

(7) Inst all a ir conditioning compressor (Fig. 8).

(8) Install accessory drive belt . Refer to Cooling


(9) Connect negative battery cable.

Fig. 6 Solid Mount Compressor Bracket 2.2 & 2.5L Engines

Fig. 7 Accessory Drive System

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POWER STEERING/ACCESSORY DRIVE BELT

TENSIONER BRACKET

REMOVAL

(1) Remove Accessory Dr ive Belt. Refer to Cooling


(2) Remove accessory drive belt tensioner pulley

(Fig. 7).

(3) Remove Timing Belt covers. Refer t o procedure


(4 ) R e m ov e P ow er S t e er i n g P u m p b ol t s s e t p u m p

aside (Fig. 11).

(5) Loosen t iming belt tension. Refer to Cam shaft

a n d C r a n k s h a ft T im i n g S e r vi ce for p r oce d u r e. R e-

move t iming belt idler pulley bolt (Fig. 12).

CAUTION: Camshaft and Crankshaft Timing may

have to be reset when procedure is completed Refer

to procedure outlined in this section.

Fig. 8 Solid Mount Compressor BracketTurbo III Engine

Fig. 9 Accessory Drive Idler Pulley Bracket andEngine Strut

Fig. 10 Compressor Bracket to Cylinder HeadAttaching Bolts

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(6) Remove Bracket bolts #2 and #3 from rear of

engine. Remove Bracket (Fig. 13).

INSTALLATION

(1) Loose assemble bracket to engine.

(2) Tighten bolts #2 and #3 to 3.3 N m (30 in. lbs.)

(Fig. 13).

(3) Tighten t iming belt idler pulley and t ighten to

54 Nm (40 ft. lbs.) (Fig. 12).

(4) Tighten bolts 32 and #3 to 54 Nm (40 ft. lbs.)(Fig. 13).

(5 ) C a m sh a ft a n d C r a n ks h a ft t im in g s h ou ld b e

checked at this t ime.

Adjust as necessary following pr ocedure outlined in

this section.

(6) Install power steering pump on bracket t ighten

bolts to 28 Nm (250 in. lbs.) torque (Fig. 11).

(7) Insta ll t iming belt covers. Refer to procedure


CAUTION: Do not use impact wrench on accessory

drive belt tensioner bolt. It may cause damage to

tensioner arm.


bolt f inger t ight. Then t ighten bolt to 54 Nm (40 ft .

l bs .) t or q u e . I n s t a ll a cce s sor y d r iv e b el t , R efe r t o

Cooling System Group 7 for procedure.

Fig. 11 Power Steering Pump Attaching Bolts

Fig. 12 Power Steering Pump Bracket and Timing

Belt Idler Bolt

Fig. 13 Power Steering Pump/Accessory Drive BeltTensioner Bracket Attaching Bolts

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TIMING SYSTEM AND SEALS SERVICE EXCEPT TURBO II I

Refer to (Fig. 1) for parts identification and torque

specifications

TIMING BELT SERVICE

(1) Remove Solid Mount Compressor Bracket. Re-

fer to procedure outlined in this section.

(2) Raise vehicle on a hoist and remove right inner

splash shield (Fig. 2).

(3 ) R em ov e s cr e w s r e t a in i n g w a t e r p u m p p u l le y

and bolts reta ining cranksh aft pulley (Fig. 3) an d lay

pullies aside.

(4) Remove nuts holding cover to cylinder head.


Fig. 3 Crankshaft and Water Pump Pulley

Fig. 1 Timing System and Seals

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(5) Remove screws holding cover to cylinder block.

(6) Remove both halves of t iming belt cover and

lay aside (Fig. 4)

(7) Place a jack under engine.

(8) Separate right engine mount (Fig. 5) and raise

engine slightly.

(9) Loosen timing belt tensioner screw (Fig. 6) and

remove timing belt.

SERVICING FRONT OIL

SEALSREPLACEMENT

(1) With t iming belt removed, r emove cranksha ft

sprocket bolt.

(2) Remove crankshaft sprocket using Special Tool

C-4685, Insert and 5.9 inch long screw (Fig. 7).

(3) Install crankshaft sprocket using plate L-4524,

Thrust Bearing/washer and 5.9 inch long screw (Fig.

7).

Fig. 4 Timing Belt Cover

Fig. 7 Crankshaft SprocketFig. 5 Right Engine Mount

Fig. 6 Remove Timing Belt

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(4) Hold engine sprocket with Special Tool C-4687

(with ada ptor Tool C-4687-1) wh ile removing/inst all-

ing screw (Fig. 8). The 2.5L Engine camshaft/inter-

mediate shaft sprockets have an off-set hub and are

identified with a six-hole pattern .

(5 ) R em ov e cr a n k s h a ft s ea l u s in g S p eci a l T ool

6341. Remove intermediate a nd camsha ft seals using

Special Tool C-4679 (Fig. 10).

CAUTION: Do not nick shaft seal surface or sealbore.

(6) Sha ft seal l ip surface m ust be free of varnish,

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

(7) Install engine crankshaft seal into retainer us-

ing Special Tool 6342 and 6343. Insta ll Intermediate

a n d C a m s h a ft s e a ls u s i n g S p eci a l T ool C -4 68 0. I n -

stall seals unt il f lush (Fig. 10).

CAMSHAFT, CRANKSHAFT AND INTERMEDIATESHAFTS TIMING PROCEDURE

(1 ) R e m ov e a l l s p a r k p lu g s. T u r n cr a n k s h a f t a n d

i n t er m e d ia t e s h a ft u n t i l m a r k i n gs on s p r ock e t s a r e

in l ine, see arrows (Fig. 11 ) .

Fig. 9 Removing Crankshaft, Intermediate Shaft andCamshaft Oil Seal

Fig. 8 Removing/Installing Camshaft or Intermediate

Shaft Sprocket Screw

Fig. 10 Installing Crankshaft,Intermediate Shaft, andCamshaft Seal

Fig. 11 Crankshaft and Intermediate Shaft Timing

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( 2 ) T u r n c a m s h a f t u n t i l a r r o w s o n h u b a r e i n l i n e

with No. 1 camshaft cap to cylinder headline. Small

hole (arrow Fig. 12) must be in vertical center l ine.

(3) Install t iming belt .

(4) Rotate crank shaft two full r evolutions and re-

check timing.

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

(5 ) R ot a t e cr a n k s h a f t t i ll n u m b e r 1 cy li n de r i s a t

the TDC position.

(6) P ut belt tension Special Tool C-4703 horizon-

tally on large hex of timing belt tensioner pulley and

loosen tensioner lock nut.(7) Reset belt tension Special Tool C-4703 index if

necessary to have axis within 15 of horizontal. (Fig.

13 )

(8) Turn en gine clockwise from TDC two cra nk revo-

lutions to TDC. D o n o t r e v e r s e r o t a t e c r a n k s h a f t

o r a t t e m p t t o r o t a t e e n g i n e u s i n g c a m o r a c c e s -

s o r y s h a f t a t t a c h i n g s c r e w .

(9) Hold weighted wr ench in position wh ile tight en-

ing bolt on tensioner to 61 Nm (45 ft. lbs.) torque.

(10) Lower engine onto engine mount inst all moun t-

ing bolts an d tighten to specificat ions refer t o (Fig. 3).(11) Remove jack from un der en gine.

(12) Inspect foam stuffer block condition a nd posi-

tion (Fig. 14). Stuffer block should be intact and secure

within the engine bra cket t unn el.

(13) Position both halves of t iming belt cover to-

gether (Fig. 4).

(14) Inst all fasteners holding cover to cylinder h ead

a n d b lock . T ig h t en fa s t e n er s t o 4 Nm (40 in. lbs.)

torque.

(15) Valve Timing Check; (t iming belt cover in-

stalled). With num ber one cylinder a t TDC, small hole

in sprocket must be centered in timing belt cover hole

(F i g. 1 2). I f h ol e i s n ot a l ig n ed cor r e ct l y p e r for mprocedure again.

(16) Install spark plugs.

Fig. 12 Camshaft Timing

Fig. 13 Adjusting Drive Belt Tension

Fig. 14 Foam Stuffer Block Location

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CYLINDER HEAD AND VALVE ASSEMBLY SERVICE EXCEPT TURBO II I

Fig. 1 Cylinder Head and Valve Assembly Service

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CYLINDER HEAD COVER AND CURTAIN

A curtain aiding air/oil separation is insta lled on

t h e cy li n d er h e a d b el ow t h e cy li n de r h e a d cov er

(Figs. 1 and 2).

REMOVAL

(1) Remove the cylinder head cover bolts (Fig. 2).

(2) Remove cylinder head cover and curt ain from

cylinder h ead. Do not misplace t he rubber bumpers

on curtain.

CLEANING

Before installation, clean cylinder head and cover

mating surfaces. Make certain the rails are flat .

CURTAIN I NSTALLATION

Install curtain manifold side first with cutouts over

cam towers and contacting cylinder head floor, then

press opposite distr ibutor side int o position below cyl-

inder head rail .

Cu r ta in is r et a in ed in p os it ion wit h r u bber

bumpers (Fig. 1).

COVER SEALING AND INSTALLATION

Before installation, clean cylinder head and cover

mating surfaces. Make certain rails are flat .

(1) Install new end seals on valve cover.

(2) Apply form-in-place Mopa r Silicone Ru bber Ad-hesive Sealant or equivalent gasket material to cyl-

i n d er h e a d cov er r a i l (F i g. 3 ). R efe r t o p r oce d u r e

detailed in form-in-place gasket section of Standa rd

Service Procedures, in this Group.

Caution: Do not allow oil or solvents to contact the

timing belt as they can deteriorate the rubber and

cause tooth skipping.

(3) Install curtain, cover and end seal assembly to

h e a d a n d t i g h t e n t o 1 2 Nm (105 in.lbs.) torque.

CYLINDER HEAD COMPONENTSIN-VEHICLESERVICE

Removal and installation of cylinder head or cam-

shaft require separation of camshaft t iming sprocket

from camshaft. To mainta in camshaft, intermediate

s h a ft , a n d cr a n k s h a ft t i m in g d u r i n g s e r vi ce p r oce -

dures, the t iming belt is left indexed on the sprocket

while the assembly is suspended under l ight tension

(Fig. 4).

W h en r e m ov in g t h e s p r ock e t fr om t h e ca m s h a ft ,

you must maintain adequate tension on the sprocket

and belt assembly to prevent the belt from disengag-

in g w it h t h e in t er m ed ia t e or cr a n ks h aft t im in g

sprockets. Refer to Timing System a nd Seals for re-

Fig. 2 Cylinder Head Cover and Curtain

Fig. 3 Cylinder Head Valve Cover Rail Sealing Fig. 4 Suspending Camshaft Sprocket

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moval and installation of camshaft sprocket proce-

d u re a n d t o C am s ha ft S er vice for r em ova l a n d

installation of camshaft procedures.

CAUTION: Failure to maintain adequate tension oncamshaft, intermediate, and crankshaft sprocketbelt can result in lost engine timing. If timing islost, refer to Timing System and Seals and (Fig. 4).

CAMSHAFT SERVICE

Refer to TIMING SYSTEM AND SEALS for cam-

shaft t iming belt and sprocket removal and installa-

tion, and CYLINDER HEAD In Vehicle Service.

REMOVAL

(1) Remove the cylinder head cover and curtain.

(2 ) M a r k r ock er a r m s for r e in s t a ll at ion in t h e

same position (Fig. 6).

(3 ) Loos e n ca m s h a ft b ea r i n g ca p s cr e w s s ev er a lrevolutions (Fig. 7).

(4 ) J a r ca m s h a ft a t r e a r of c a m t o l oos e n (b r ea k

free) the bearing caps. U s e a s o f t f a c e d m a l l e t .

CAUTION: Care should be exercised not to cock the

camshaft during removal. Cocking of the camshaft

could cause damage to the cam or bearing thrust

surfaces.

(5 ) R em ov e s c r ew s a n d ca p s s u ch t h a t ca m d oe s

not cock.

INSPECTIONCheck bearing cap and oil feed holes for blockage.

Inspect bearing cap and cylinder head journals for

wear and/or oversize, Refer to CYLINDER HEAD,

I n s p e c t and Specifications.

Fig. 5 Engine Sprocket Timing

Fig. 6 Rocker Arm and Lash Adjuster

Fig. 7 Camshaft Cap Removal Sequence

Fig. 8 Camshaft

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C a m s h a ft b ea r i n g jou r n a l s a n d l ob e w ea r . L ob e

wear should not exceed .25mm (.010 inch). To m ea-

sure cam lobe wear (Fig. 8), m easure lobe diameter

in two places at the largest diameter (over the nose).

T a k e f ir s t r e a d in g w it h m i cr om e t er i n u n w or n a r e a

a t t h e e d g e o f t h e l o b e . T a k e s e c o n d r e a d i n g i n t h e

worn area where rocker arm contacts the lobe. Sub-

tract second reading from the first . The difference isthe cam lobe wear.

CAMSHAFT END PLAY

(1 ) O il ca m s h a ft jou r n a ls a n d in s t a ll ca m s h a ft

without cam followers. Tighten screws to specified

torque.

(2 ) U s in g a s u i t a bl e t ool , m o ve ca m s h a ft a s fa r

rearward as i t will go.

(3) Zero dial indicator (Fig. 9).

(4) Move camshaft as far forward as i t will go.

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

inch.).

(6) Remove bearing caps and camshaft.

INSTALLATION

(1 ) I n s t a ll ca m fol low er s i n cor r e ct or d e r a s r e -

moved.

(2) Align camshaft bearing caps in proper sequence

w i t h C a p N o . 1 a t t i m i n g b e l t e n d a n d C a p N o . 5 a t

t r a n s m is sion e n d. Ar r ow s on C a ps N o. 1 , 2 , 3 , 4

m u s t point toward t iming belt to prevent cap break-

age (Fig. 11).

(3) Apply Mopar Gasket Maker to No.1 and No.5

bearing cap (Fig. 10).

(4 ) C a p s m u s t b e i n s t a ll ed b efor e ca m s h a ft s e a ls

are installed.

LASH ADJUSTER (TAPPET) NOISE

A ta ppet-like noise may be pr oduced from several

items. Refer to Lash Adjuster and Tappet Noise - Di-

agnosis in Standard Service Procedures, this Group.

VALVE COMPONENTS REPLACECYLINDER

HEAD NOT REMOVED

ROCKER ARM AND HYDRAULIC LASH

ADJUSTER

REMOVAL

(1) Rem ove va lve cover.

(2) For each rocker arm, rotate cam until base cir-

cle i s in con t a ct w it h r ock e r a r m . D ep r es s v a lve

spring using Special Tool C-4682 (Fig. 12) and slide

rocker arm out. Keep rocker arms in order for reas-

sembly.

(3) Remove hydraulic lash adjuster.

INSTALLATION

(1 ) In s t a l l h y dr a u l ic l a sh a d ju s t e r s m a k i n g s u r e

that adjusters are at least partially full of oil . This is

indicated by l it t le or n o plunger travel when the lash

adjuster is depressed.

(2) Rotate cam until base circle is in contact posi-

tion with rocker arm. Depress valve spring with Spe-

cial Tool C-4682 (Fig. 12) and slide rocker arm in

p la ce . K ee p r ock e r s i n or d e r . I t i s p os s ib le for t h e

Fig. 9 Camshaft End Play

Fig. 10 Cam Tower Cap Sealing

Fig. 11 Camshaft Bearing Caps Installation

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v a lv e s p r in g r e t a in e r l ock s t o b ecom e d is loca t e d

when depressing the valve spring.C h e c k a n d m a k e

s u r e t h e l o c k s a r e i n t h e i r p r o p e r l o c a t i o n .

(3) Install valve cover as previously outlined inthis section.

VALVE SPRINGS AND VALVE STEM SEALS

REMOVAL

(1) Remove r ocker arms as previously outlined in

this section.

(2 ) R ot a t e cr a n k s h a ft u n t il p is t on is a t T DC on

compression.

(3) With air hose attached to adapter tool installed

in spark plug hole, apply 90-120 psi air pressure.

(4) U sing Special Tool C-4682 (Fig. 12) compress

valve springs and remove valve locks.

(5) Remove valve spring.

(6) Remove valve stem seal by gently prying side-

to-side with a screwdriver blade. Once dislodged from

guide post, seal may be easily removed.

INSTALLATION

CAUTION: Flexible Fuel Vehicle Valve use unique

valve stem oil seals they are green in color. Stan-

dard valve stem oil seals are NOT to be interchanged

with Flexible Fuel Vehicles engines.

(1) Install valve seals (Fig. 13) as outlined in step

(2) of V a l v e G e a r R e a s s e m b l y - A f t e r V a l v e S e r -

v i c e in this section.

(2 ) U s in g S p eci a l T ool C -4 68 2 com p r e ss v a lv e

springs only enough to install locks. Correct align-

m e n t of t ool is n e ce ss a r y t o a void n i ck in g va lv e

stems (air pressure required), piston at TDC.

(3 ) I n s t a l l r ock e r a r m s a s p r e vi ou s l y ou t l in e d i n

this section.

CYLINDER HEAD

REMOVAL

(1) Perform fuel system pressure release procedure

b e f o re a t t e m p t i n g a n y r e p a i rs .R efe r t o F u e l S ys -

tem Group 14

(2) Disconnect n egative bat tery cable. Dra in cool-

ing system. Refer to Cooling System, Group 7.

(3) Remove a ir cleaner and disconnect all vacuum

lines, electrical wiring and fuel l ines from thr ottle

body.

(4) Remove throttle linkage.

(5) Loosen power steering pump and remove belt .

(6) Remove power brake vacuum hose from intake

manifold.

(7) Remove water hoses from water crossover.(8 ) R a is e v eh i cl e a n d r e m ov e e xh a u s t p ip e fr om

manifold.

(9) Remove power steering pump assembly and set

aside.

(10) Disconnect coil wiring connector and coil wire

from coil.

(1 1) D is con n e ct d ip s t ick t u b e fr om t h e r m os t a t

h o u s i n g a n d ROTATE bracket from stu d.D O N O T

bend the bracket or tube.

(1 2) S ee S ol id M ou n t C om p r es sor B r a ck et in

STANDARD SERVICE PROCEDURES, th is Group.

(13) Remove cylinder head bolts.

INSPECT HEAD AND CAMSHAFT BEARING

JOURNALS

(1) Cylinder head must be flat within 0.1mm (.004

inch) (Fig. 14).

(2) Inspect camshaft journals for scoring and jour-

nal caps for oversize markings. When servicing cyl-

inder head or camshaft, i t is necessary to be certain

tha t oversized camsha fts are used only in oversized

heads.

I d e n t i f y o v e r s i z e c o m p o n e n t s a s f o l l o w s :

Fig. 12 Removing and Installing Valve SpringFig. 13 Valve Stem Seals

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Cylinder Head: Top of bearing caps painted g r e e n

and O/SJ stamped r earward of oil gallery plug on end

of head.

C a m s h a ft : B a r r e l of ca m s h a ft p a in t e d g r e e n a n d

O/SJ stamped on end of shaft.

CLEANING

Remove all gasket material from cylinder head and

block. Be careful not gouge or scratch the aluminum

head sealing surface.

INSTALLATION

CAUTION: Head bolt diameter is 11mm. These bolts

are identified with 11 on the head of the bolt. 10mm

bolts will thread into the 11mm hole but will strip thecylinder block bolt hole.

S i n c e t h e C y l i n d e r h e a d b o l t s a r e t o r q u e d u s -

i n g a n e w p r o c e d u r e t h e y s h o u l d b e e x a m i n e d

B E F O R E r e u s e . I f t h e t h r e a d s a r e n e c k e d d o w n

t he bo l t s s ho ul d be r e pl a c e d ( F i g . 1 6 ) .

Necking can be checked by holding a scale or straight

e dg e a g a in s t t h e t h r e a ds . I f a l l t h e t h r e a ds d o n ot

contact the scale the bolt should be replaced.

(1) Before installing the bolts the threads should be

oiled with engine oil.

(2) Install both bolts in each cap finger t ight, then

alternately torque each bolt to assemble the cap prop-

erly.

(3) Tighten the cylinder head bolts in the sequence

s h ow n in (F ig. 1 7). U s in g t h e 4 s t ep t or q u e t u r n

meth od, tighten according to t he following values:

First All to 61 Nm (45 ft. lbs.)

Second All to 88 Nm (65 ft. lbs.)

Third All (again) to 88 Nm (65 ft., lbs.)

Fourth + 1/4 Turn D o n o t u s e a t o r q u e w r e n c h

f o r t hi s s t e p.

Bolt t orque after 1/4 tur n should be over 90 ft. lbs. If

not, replace the bolt.

(4 ) R ot a t e d ip s tick t u b e or b r a ck et on t o s t u d.

T igh t e n b r a ck e t r e t a in in g n u t t o 2 3 Nm (2 00 in .

lbs.)

VALVE SERVICE CYLINDER HEAD REMOVED

VALVES AND V ALVE SPRINGS

REMOVAL

(1) With cylinder head removed, compress valve

Fig. 15 Cylinder Head Gaskets

Fig. 16 Checking Bolts for Stretching (Necking)

Fig. 17 Cylinder Head Tightening Sequence

Fig. 14 Checking Cylinder Head Flatness

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springs using Tool C-3422-B.

(2) Remove valve retaining locks, valve spring re-

tainers, valve stem seals and valve springs.

(3) Before removing valves,re m ov e a n y b urrs

f ro m v a l v e s t e m l o c k g r o o v e s t o p r e v e n t d a m a g e

t o t h e v a l v e g u i d e s . Identify valves to insure instal-

lation in original location.

VALVE INSPECTION

(1 ) C le a n v a lv es t h or ou g h ly a n d d is ca r d b u r n e d,

warped and cracked valves.

(2) Measure valve stems for wear.

(3) If valve stems a re worn more tha n 0.05 mm (.002

inch.) replace valve.

VALVE GUIDES

(1) Remove carbon a nd va rnish deposits from inside

of valve guides with a reliable guide cleaner.

(2) Checking Valve Guide Wear:

Insert valve with valve head positioned 10 mm (.400

inch) above cylinder head gasket surface. Move valve to and from the indicator (Fig. 17). The

total dial indicator reading should not exceed the amount

specified in (Fig. 18). Readings should be taken for length-

wise an d crosswise (with r espect to cylinder head) m ove-

ment for each valve. Ream t he guides for valves with

oversize stems if dial indicator reading is excessive or if

the stems are scuffed or scored.

(3) Service valves with oversize stems and oversizeseals a re available in 0.15mm, (.005 inch) 0.40mm,

(.015 inch) and 0.80mm(.031 inch) oversize.

Ov e rs iz e s e a ls m u s t b e u s e d w i th o v e rs iz e

v a l v e s .

Reamers sizes to accommodate the oversize valve

stem are shown in (Fig. 18)

(4) Slowly turn reamer by hand and clean guide thor-

oughly before installing new valve. D o n o t a t t e m p t t o

r e a m t h e v a l v e g u i d e s f r o m s t a n d a r d d i r e c t l y t o

0. 80m m ( . 030 i n ch ) . U se st ep p roced u re of 0. 15m m

( .005 i n c h ) , 0. 40m m ( .015 i n c h ) an d 0.80m m ( .030

i n c h ) s o t h e v a l v e g u i d e s m a y b e r e a m e d t r u e i n

rel at i on t o t h e val ve se at . A ft er ream i n g gu i d es, t h e

s e a t r u n o u t s h o u l d b e m e a s u r e d a n d r e s u r f a c e d i f

nec ess ary. Refer to Refacin g Valves a nd Valve Se ats.

R e p l a c e c y l i n d e r h e a d i f g u i d e d o e s n o t c l e a n

up w i t h 0 .8 0 m m ( . 03 0 i nc h) o v e r s i z e r e a m e r, o r i f

g u i d e i s l o o s e i n c y l i n d e r h e a d .

TESTING VALVE SPRINGS

(1) Whenever valves have been r emoved for insp ection,

recondit ioning or replacement, valve springs should be

t e s t ed . As a n e xa m p l e, t h e com p re ss i on l en g t h of t h e

spring t o be tested is 33.34mm (1-5/16 inches). Tur n ta ble

of Tool C-647 until surface is in line with the 33.34mm

(1 -5 / 1 6 i n c h ) m a rk o n t h e t h re a d e d s t u d a n d t h e z e ro

mark on the front. Place spring over stud on the table andlift compressing lever to set tone device (Fig. 20). Pull on

torque wrench un til ping is hear d. Take rea ding on torque

wrench at this instant. Multiply this reading by two. This

will give the spring load at test length. Fractional mea-

s u re m en t s a re i n d ica t e d on t h e t a b le for fi n er a d ju s t -

ments. Refer to specifications to obtain specified height

and al lowable tensions. Discard the springs that do not

meet specifications.

Fig. 18 Checking Wear on Valve GuideTypical

Fig. 19 Valve Guide Specification

Fig. 20 Testing Valve Spring with Tool C-647

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(2) Inspect each valve spring for squareness with a

steel square and surface plate, test springs from both

e n d s. I f t h e s p r in g i s m o r e t h a n 1 .5 m m (1 /1 6 i n ch )

out of square, install a new spring.

REFACING VALVES AND VALVE SEATS( 1 ) T h e i n t a k e a n d e x h a u s t v a l v e s e a t s a n d v a l v e

face have a 45 degree angle.

(2) Inspect the remaining margin after the valves are

r efa ce d (F ig. 2 3). E xh a u st va lve s w it h le ss t h a n

1.191mm (3/64 inch) margin and intake valves with less

than .794mm (1/32 inch) margin should be discarded.

(3 ) Wh e n re fa ci n g v a l ve s e a t s , i t i s i m p ort a n t t h a t

the correct size valve guide pilot be used for reseating

stones. A true and complete surface must be obtained.

(4) Measure the concentricity of valve seat using a

valve seat dial indicator. Total ru nout should not ex-

ceed. 051mm (.002 inch) (total indicator reading).(5) Inspect t he valve seat with Pru ssian blue to deter-

mine where the valve conta cts the seat . To do this, coat

valve seat LIGHTLY with Prussian blue then set valve

i n p la ce . R ot a t e t h e v a lv e w i t h l ig h t p re ss u re . I f t h e

blue is t ransferred t o the center of valve face, conta ct is

satisfactory. If the blue is t ransferred to top edge of the

valve face, lower valve seat with a 15 degrees stone. If

the blue is t ransferred to the bottom edge of valve face

raise valve seat with a 65 degrees stone.

Intake valve seat diameter 40.45mm (1.593 inch)

Exhaust valve seat diameter 34.84mm (1.371 inch)

Va l ve s ea t s w h ich a r e w or n or b u r n ed ca n b e r e -

worked, provided that correct angle and seat width are

maintained. Otherwise cylinder head must be replaced.

(6) When seat is properly positioned the width of

intake seats should be 1.75 to 2.25mm (0.69 to .088

inch) The width of the exhaust seats should be 1.50

to 2.00mm (.059 to .078 inch) (Fig. 24 Dimension 1).

(7 ) C h e ck v a lv e t i p t o s p rin g s e a t d im e n s ion s a ft e r

grinding t he valve seat s or faces. Grind valve t ip to get

49.76 to 51.04mm (1.960 to 2.009 inch) over spring seat

when instal led in the head (Fig. 25). The valve t ip di-

a m e t e r s h ou l d b e n o l e s s t h a n 7 .0 m m (0 .2 75 i n ch ), i f

n e ce s sa ry , t h e t i p ch a m fer s h ou l d b e r e grou n d t o p re -vent seal damage when the valve is instal led.

Fig. 21 Intake and Exhaust Valves

Fig. 22 Valve Dimensions

Fig. 23 Refacing Intake and Exhaust Valves

Fig. 24 Refacing Valve Seats

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(8 ) C h e ck t h e v a lv e s p r in g i n st a l le d h e ig h t a ft e r

refacing the valve and seat (Fig. 26).

CAUTION: If more than .5mm (.020 inch) must be

ground from the valve tip, check the clearance be-

tween the rocker arm and the valve spring retainer

if below 1.25mm (.050 inch), grind the rocker arm

ears according to the procedure described in Refac-ing Valves and Valve Seats.

CLEANING

Clean all valve guides, valves and valve spring as-

semblies thoroughly with suitable cleaning solution

before reassem bling.

VALVE GEAR REASSEMBLY AFTER VALVE SERVICE

(1) Coat valve stems with lubrication oil and insert

in cylinder head.

CAUTION: Flexible Fuel Vehicles use unique valvestem oil seals they are green in color. Standardvalve stem oil seals are NOT to be interchanged withFlexible Fuel Vehicles engines.

(2) Install new valve stem seals on all valves. The

va lve s t em s ea ls s h ou ld be p u sh ed fir m ly a n d

squarely over valve guide. The lower edge of the seal

should be resting on the valve guide boss.

CAUTION: When oversize valves are used, the cor-responding oversize valve seal must also be used.Excessive guide wear may result if oversize sealsare not used with oversize valves.

( 3 ) I n s t a l l v a l v e s p r i n g s e a t s a n d s p r i n g s a n d r e -

tainers. Compress valve springs only enough to in-

stall locks, taking care not to misalign the direction

of compression. Nicked valve stems may result from

misalignment of the valve spring compressor.

CAUTION: When depressing the valve spring retain-ers with Tool C-3422-B the locks can become dislo-cated. Check to make sure both locks are in theircorrect location after removing tool.

(4) Check installed height of springs. Measurement

i s t o b e t a k e n f r o m t h e s p r i n g s e a t t o t h e b o t t o m o f

t h e s pr in g r e t a in e r . C or r e ct h e igh t is 4 1. 2m m t o

42.7mm (1.62 to 1.68 inches). If seats have been re-

g r ou n d a n a d d it i on a l s p r in g s e a t m a y b e r e q u ir e d t o

maintain correct installed spring height.

(5 ) In s t a ll a d ju s t er s , r ock er a r m s i n or d er , a n d

camsha ft as previously described, see Camshaft-In-

stall. Check for clearance between the projecting ears

(either side of valve t ip) of the rocker arms and the

valve spring retainers. At least 1.25 mm (.050 inch)

cl ea r a n c e m u s t b e p r e se n t , i f n e ce s sa r y , t h e r ock e r

a r m e a r s m a y b e g r ou n d t o o bt a in t h is cle a r a n ce

(Fig. 26).

(6 ) C h e ck i n g d r y l a s h . D r y l a sh i s t h e a m ou n t of

clearance that exists between the base circle of an in-

s t a l l e d c a m a n d t h e r o c k e r a r m r o l l e r w h e n t h e a d -

ju st er is dr a in ed of oil a n d com pl et ely colla ps ed .

Specified dry lash is 0.62 t o 1.52 mm (.024 to .060

inch). To completely collapse adjuster for dry lash

m e a su r e me n t , p r y off r e t a in e r ca p , d is a ss em b le ,

drain the adjuster of oil , reassemble, and install . Af-

ter performing dry lash check, refill adjuster with oil

(do not reuse retainer cap/s) and allow 10 minutes for

adjuster/s to bleed down before rotating cam.

Fig. 25 Valve Tip to Spring Seat Dimensions

Fig. 26 Checking Spring Installed Height and Spring

Retainer Clearance

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CYLINDER HEAD AND VALVE ASSEMBLYSERVICE TURBO II I

CYLINDER HEAD COVER SEALING

(1) Before inst allat ion, clean cylinder hea d an d cover

mating surfaces. Make certain r ails are flat .

Caution: Do not allow oil or solvents to contact the

timing belt as they can deteriorate the rubber and

cause tooth skipping.

(2) Install covers and gasket assembly to head and

torque to 12 Nm (105 in.lbs.).

CYLINDER HEAD

REMOVAL

R efe r t o I n t a k e a n d E x h a u s t M a n ifol d S e r vi ce i n

Exhaust Systems and Intake Manifold Group 11 for

removal procedure for the intake and exhaust mani-

folds.

(1) The Timing Belt and Solid Mount Compressor

Mount Bracket must be removed before the cylinder

head can be removed. Refer to procedure outlined in

th is group for service pr ocedures.

(2) Remove cylinder head bolts.

(3) Cylinder head must be flat within 0.1mm (.004

inch) (Fig. 2).

INSTALLATION

CAUTION: The Turbo III head gasket is not the same

as any other engine head gasket (Fig. 3).

CAUTION: Head bolt diameter is 11mm. These bolts

are Unique to this engine application they are not

interchangeable with other engines.

T h e C y l i n d e r h e a d b o l t s a r e t o r q u e d u s i n g a

n e w p ro c e du r e t h e y s h o u ld b e e x a mi n e d B E -

F O RE r e u s e . If t h e t h r e a d s a r e n e c k e d d o w n t h e

bo l t s s ho ul d be r e pl a c e d. ( F i g . 4 ) .

N eck in g ca n b e ch e ck e d b y h old in g a s ca le or

s t r a i g h t e d g e a g a i n s t t h e t h r e a d s . I f a l l t h e t h r e a d s

do not contact the scale the bolt should be replaced.

Fig. 2 Checking Cylinder Head Flatness

Fig. 3 Cylinder Head Gaskets

Fig. 4 Checking Bolts for StretchingNecking

Fig. 1 Cylinder Head Valve Cover and Gasket As-sembly

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B efor e i n st a l li n g t h e b ol t s, t h e t h r e a d s s h ou l d b e

cleaned and oiled.

T ig h t en t h e cy li n d er h e a d b ol t s i n t h e s e qu e n ce

s h ow n in (F ig. 5 ). U sin g t h e 4 s t ep t or qu e t u r n

method, tighten according to the following values:

First All to 61 Nm (45 ft. lbs.)

Second All to 88 Nm (65 ft. lbs.)

Third All (again) to 88 Nm (65 ft., lbs.)

F ou r t h + 1 /4 T u r n D o n o t u s e t o r q u e w r e n c h

f o r t h i s s t e p .

Bolt torque after 1/4 turn should be over 90 ft. lbs.

If not, replace the bolt .

R efe r t o I n t a k e a n d E x h a u s t M a n ifol d S e r v ice i n

Exhaust Systems and Intake Manifold Group 11 for

installation procedure.

R efe r t o t h e T im i n g B e lt a n d S ol id M ou n t C om -

p r e ss or M ou n t B r a ck e t s e r vi ce p r oce d u r es i n t h i sgroup for installations procedures.

TIMI NG BELT COVER SERVICETURBO III

ENGINE

REMOVAL

(1) Remove PCV tube and upper t iming belt cover

screws (Fig. 1). Remove upper cover.

(2) Rem ove accessory drive belt. Refer to Cooling

System Group 7 for procedure.(3 ) R a is e v eh icle on a h oi st a n d r e m ov e r ig h t

wheel and inner splash shield (Fig. 2).

(4) Remove water pump pulley and crankshaft pul-

ley retaining bolts (Fig. 3), remove pulleys.

(5) Remove lower accessory drive belt idler and

tensioner pulley (Fig. 4).

Fig. 1 Timing Belt Cover Screws

Fig. 5 Cylinder Head Tightening Sequence


Fig. 3 Crankshaft and Water Pump Pulleys

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CAUTION: Do not use a impact wrench to remove

pulley bolts.

(6) Remove lower timing belt cover fasteners (Fig.

1). Remove cover.

INSTALLATION

(1) Raise vehicle on hoist. Install lower timing belt

c o v e r a n d t i g h t e n f a s t e n e r s t o 1 2 Nm (105 in. lbs.)

torque (Fig. 4).

CAUTION: Do not use impact wrench on accessory

drive belt tensioner bolt. It may cause damage to

tensioner arm. Accessory drive belt tensioner pul-

ley bolt must be installed finger tight.


bolt f inger t ight. Then t ighten bolt to 54 N m (40 ft.

lbs.) torque (Fig. 4).

(3 ) I n st a ll cr a n k s h a ft a n d w a t er p u m p p u lle ys

(Fig. 3).

(4) Install inner splash shield and wheel (Fig. 2).

(5) Install accessory drive belt . Refer to Cooling


(6 ) In s t a ll u p p er t im in g b elt cove r a n d t igh t e n

screws to 4 Nm (36 in. lbs.)

engine 3.0 v6

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