Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual — part 7
1-26
Chapter 1 Tune-up and routine maintenance
V6 engine
Refer to illustration 29.15
Note: On V6 engines, the manufacturer rec-
ommends replacing the spark plugs, spark
plug wires, distributor cap and rotor at the
same time.
11
Remove the upper intake manifold (see
Chapter 2B).
12
To prevent dirt or other foreign debris
from entering the engine, place duct tape
over the openings of the lower intake mani-
fold.
13
Remove the EGR tube from the EGR
valve (see Chapter 6 if necessary).
14
Disconnect one spark plug wire from the
distributor cap. Pull only on the boot at the
end of the wire; don't pull on the wire itself.
Use a twisting motion to free the boot/wire
from the distributor. Install the removed wire
into the new distributor cap in the exact same
location. Repeat this procedure until all spark
plug wires are installed in the new cap.
15
Loosen the 2 screws and remove the old
distributor cap (see illustration). Remove the
rotor.
16 Install the new rotor and distributor cap
(with spark plug wires attached).
17
Replace the spark plugs as described in
Section 27, except do not reattach the spark
plug wires to the retaining clips.
18
Replace the spark plug wires one at a
ti me to avoid mixing up the firing order and
make sure the terminals are securely seated
on the distributor cap and the spark plugs.
Install the plug wires using a twisting motion
on the boot until it is firmly seated. Attach the
spark plug wire to any retaining clips as
required.
19
Using a new gasket, install the EGR
1
The manufacturer does not suggest
tube onto the EGR valve (see Chapter 6).
periodic fuel filter replacement on JA series
Tighten the bolts to the torque given in the
models. See Chapter 4 if the fuel filter
Specification Section of Chapter 6.
requires replacement due to a fuel restriction
20
Remove the duct tape from the lower
or fuel contamination problem.
intake manifold.
21
Install the upper intake manifold (see
Chapter 2B).
29.15 Distributor cap
retaining screw locations
(V6 engines only)
30 Fuel filter - replacement
Chapter 2 Part A
Four-cylinder engines
Contents
Section
Balance shafts (2.4L engine) . . . . . . . . . . ..See Chapter 2C
Camshafts - removal, inspection and installation . . . . . . . . 10
Camshaft oil seal - replacement . . . . . . . . . . . . . . . 8
CHECK ENGINE light . . . . . . . . . . . . . ... See Chapter 6
Crankshaft front oil seal - replacement . . . . . . . . . . . . . 7
Cylinder head - removal and installation . . . . . . . . . . . ..12
Engine mounts - check and replacement . . . . . . . . . . . 17
Exhaust manifold - removal and installation. . . . . . . . . . ..5
Driveplate - removal and installation . . . . . . . . . . . . . 15
General information. . . . . . . . . . . . . . . . . . . . 1
Intake manifold - removal, inspection and installation . . . . . . .. 4
Section
Oil pan - removal and installation. . . . . . . . . . . . . . 13
Oil pump - removal, inspection and installation . . . . . . . . ...14
Rear main oil seal - replacement. . . . . . . . . . . . . . .16
Repair operations possible with the engine in the vehicle. . . . . 2
Rocker arm and hydraulic valve lash adjuster - removal,
inspection and installation . . . . . . . . . . . . . . . . 9
Timing belt - removal, inspection and installation . . . . . . . . . 6
Top dead center (TDC) for number one piston . . . .. See Chapter 2C
Valve cover - removal and installation. . . . . . . . . . . . ...3
Valve springs, retainers and seals - replacement . . . . . . . . 11
Specifications
General
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke
2.0L. . . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
Compression ratio
2.0L. . . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
Compression pressure. . . . . . . . . . . . . . . . . . .
Displacement
2.0L. . . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
Firing order. . . . . . . . . . . . . . . . . . . . . . . ..
Oil pressure
At idle speed. . . . . . . . . . . . . . . . . . . . . ..
At 3000 rpm . . . . . . . . . . . . . . . . . . . . . ...
3.445 inches
3.268 inches
3.976 inches
9.8:1
9.4:1
Front
170 to 225 psi
Of
Vehicle
122 cubic inches
148 cubic inches
1-3-4-2
4 psi (minimum)
25 to 80 psi
Cylinder numbering and coil
terminal locations
2A-2
Chapter 2 Part A Four-cylinder engines
Camshaft
Bearing journal diameter
2.0L
No. 1. . . . . . . . . . . . . . . . . . . . . . . .
No. 2. . . . . . . . . . . . . . . . . . . . . . . .
No. 3. . . . . . . . . . . . . . . . . . . . . . . .
No. 4. . . . . . . . . . . . . . . . . . . . . . . .
No. 5. . . . . . . . . . . . . . . . . . . . . . . .
2.4L . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing bore diameter
2.0L
No. 1. . . . . . . . . . . . . . . . . . . . . . . ..
No. 2. . . . . . . . . . . . . . . . . . . . . . . .
No. 3. . . . . . . . . . . . . . . . . . . . . . . .
No. 4. . . . . . . . . . . . . . . . . . . . . . . .
No. 5. . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
Bearing clearance. . . . . . . . . . . . . . . . . . . . ...
Endplay
2.0L
2.4L
Lobe lift
2.0L
Intake. . . . . . . . . . . . . . . . . . . . . . .
Exhaust. . . . . . . . . . . . . . . . . . . . . . .
2.4L
Intake. . . . . . . . . . . . . . . . . . . . . . .
Exhaust. . . . . . . . . . . . . . . . . . . . . . .
Cylinder head
Head gasket surface warpage limit . . . . . . . . . . . . . . .
Exhaust manifold mounting surface warpage limit . . . . . . . . .
Intake and exhaust manifolds
Warpage limit. . . . . . . . . . . . . . . . . . . . . . ..
Rocker arm shaft assemblies (2.0L engine only)
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . ..
Rocker arm inside diameter . . . . . . . . . . . . . . . . .
Rocker arm-to-shaft clearance . . . . . . . . . . . . . . . ...
Rocker arm shaft retainer width
Intake. . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
No. 1 and No. 5. . . . . . . . . . . . . . . . . . .
No. 2, No. 3 and No. 4. . . . . . . . . . . . . . . . ..
Oil pump
Cover warpage limit. . . . . . . . . . . . . . . . . . . .
Inner rotor thickness
2.0L. . . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
Outer rotor thickness
2.0L. . . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
Outer rotor diameter . . . . . . . . . . . . . . . . . . . .
Rotor-to-pump cover clearance . . . . . . . . . . . . . . . ..
Outer rotor-to-housing clearance. . . . . . . . . . . . . . .
Inner rotor-to-outer rotor lobe clearance . . . . . . . . . . . .
Pressure relief spring free length . . . . . . . . . . . . . . . .
Torque specifications
Camshaft bearing cap bolts
M6 bolts . . . . . . . . . . . . . . . . . . . . . . . .
M8 bolts . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft position sensor bolts
2.0L. . . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
1.619 to 1.6199 inches
1.634 to 1.635 inches
1.650 to 1.651 inches
1.666 to 1.668 inches
1.682 to 1.6829 inches
1.021 to 1.022 inches
1.622 to 1.6228 inches
1.637 to 1.638 inches
1.653 to 1.654 inches
1.669 to 1.670 inches
1.685 to 1.6858 inches
1.024 to 1.025 inches
0.0027 to 0.003 inch
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
0.0059 inch
0.002 to 0.006 inch
0.307 inch
0.277 inch
0.324 inch
0.256 inch
0.004 inch maximum
0.006 inch maximum (per foot)
0.006 inch maximum (per foot)
0.786 to 0.7867 inch
0.787 to 0.788 inch
0.0006 to 0.0021 inch
1.12 inches
1.14 inches
1.59 inches
0.003 inch
0.301 inch (minimum)
0.370 inch (minimum)
0.301 inch (minimum)
0.370 inch (minimum)
3.148 inch (minimum)
0.004 inch
0.015 inch (maximum)
0.008 inch (maximum)
2.39 inches (approximate)
Ft-lbs (unless otherwise indicated)
105 in-lbs
250 in-lbs
85 in-lbs
20
Chapter 2 Part A Four-cylinder engines
2A-3
Torque specifications (continued)
Ft-lbs (unless otherwise indicated)
Camshaft sprocket/pulley bolt
2.0L. . . . . . . . . . . . . . . . . . . . . . . . . . . .85
2.4L. . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Crankshaft damper bolt. . . . . . . . . . . . . . . . . . . . ... 100 to 105
Cylinder head bolts
Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . .25
Step 2. . . . . . . . . . . . . . . . . . . . . . . . . 50
Step 3. . . . . . . . . . . . . . . . . . . . . . . . . 50
Step 4. . . . . . . . . . . . . . . . . . . . . . . . . Tighten an additional 1/4 turn (90-degrees)
Engine mounting bracket bolts. . . . . . . . . . . . . . . . . . 30 to 45
Exhaust manifold-to-cylinder head bolts . . . . . . . . . . . . . . .200 in-lbs
Exhaust manifold-to-exhaust pipe bolts . . . . . . . . . . . . . . ..20
Exhaust manifold heat shield bolts . . . . . . . . . . . . . . . . .. 105 in-lbs
Front engine mount strut and structural collar bolts (1998 2.4L engine only) (see illustration 13.16)
Bolts 1 through 3. . . . . . . . . . . . . . . . . . . . . . 75
Bolts 4 through 8. . . . . . . . . . . . . . . . . . . . . . 45
Driveplate-to-crankshaft bolts . . . . . . . . . . . . . . . . . . . 70
Intake manifold bolts
2.0L (plastic manifold) . . . . . . . . . . . . . . . . . . . . .105 in-lbs
2.4L (aluminum manifold) . . . . . . . . . . . . . . . . . . ... 200 in-lbs
Oil filter adapter fastener . . . . . . . . . . . . . . . . . . . . ..60
Oil pan bolts . . . . . . . . . . . . . . . . . . . . . . . . . .105 in-lbs
Oil part-to-transaxle structural collar bolts (1997 2.4L and 1998 2.0L engines only)
Step 1 (collar-to-oil pan bolts) . . . . . . . . . . . . . . . . . 30 in-lbs
Step 2 (collar-to-transaxle bolts) . . . . . . . . . . . . . . . . 80
Step 3 (collar-to-oil pan bolts) . . . . . . . . . . . . . . . . . 40
Oil pump
Attaching bolts. . . . . . . . . . . . . . . . . . . . . . . 250 in-lbs
Cover screws. . . . . . . . . . . . . . . . . . . . . . . ..105 in-lbs
Pick-up tube bolt. . . . . . . . . . . . . . . . . . . . . . 250 in-lbs
Relief valve cap bolt. . . . . . . . . . . . . . . . . . . . ... 30
Rocker arm shaft bolts (2.0L) . . . . . . . . . . . . . . . . . . ...250 in-lbs
Thermostat housing bolts. . . . . . . . . . . . . . . . . . . . 200 in-lbs
Timing belt
Cover bolts
2.0L. . . . . . . . . . . . . . . . . . . . . . . . . . 105 in-lbs
2.4L
Outer-to-inner attaching bolts . . . . . . . . . . . . . . . 40 in-lbs
Inner cover-to-head/oil pump bolts. . . . . . . . . . . . .105 in-lbs
Tensioner bolts
Mechanical type . . . . . . . . . . . . . . . . . . . . . . . 250 in-lbs
Hydraulic type
Tensioner pulley assembly plate bolts . . . . . . . . . . . . ..23
Tensioner unit bolts. . . . . . . . . . . . . . . . . . . ...23
Tensioner pulley bolt. . . . . . . . . . . . . . . . . . . .30
Timing belt idler pulley bolt (2.4L). . . . . . . . . . . . . . . . . 45
Valve cover bolts. . . . . . . . . . . . . . . . . . . . . . . ..105 in-lbs
Water pump mounting bolt. . . . . . . . . . . . . . . . . . . .. 105 in-lbs
*Refer to Part C for additional torque specifications
2A
2A-4
Chapter 2 Part A Four-cylinder engines
3.6a Remove the valve cover mounting bolts .. .
L
3.6b ... and lift the cover and gasket off the cylinder head
1
General information
This Part of Chapter 2 is devoted to in-
vehicle engine repair procedures on models
equipped with 2.0 liter and 2.4 liter four-cylin-
der engines. Information concerning engine
removal and installation and engine block
and cylinder head overhaul can be found in
Part C of this Chapter.
The following repair procedures are
based on the assumption that the engine is
installed in the vehicle. If the engine has been
removed from the vehicle and mounted on a
stand, many of the steps outlined in this Part
of Chapter 2 will not apply.
The Specification Section included in
this Part of Chapter 2 apply only to the proce-
dures contained in this Part. Part C of Chap-
ter 2 contains the Specification Section nec-
essary for cylinder head and engine block
rebuilding.
There are two four-cylinder engines
installed in the models covered in this man-
ual; the 2.0L Single Overhead Camshaft
(SOHC) engine and the 2.4L Double Over-
head Camshaft (DOHC) engine. The main dif-
ference between the 2.0 liter and 2.4 liter
engines, besides the obvious engine dis-
placement, is the incorporation of two bal-
ance shafts installed below the crankshaft of
the 2.4L engine. For service information on
the balance shafts refer to Part C of this
Chapter.
2
Repair operations possible with
the engine in the vehicle
Many major repair operations can be
accomplished without removing the engine
from the vehicle.
Clean the engine compartment and the
exterior of the engine with some type of
degreaser before any work is done. It will
make the job easier and help keep dirt out of
the internal areas of the engine.
Depending on the components involved,
it may be helpful to remove the hood to
improve access to the engine 'as repairs are
performed (refer to Chapter 11 if necessary).
Cover the fenders to prevent damage to the
paint. Special pads are available, but an old
bedspread or blanket will also work.
If vacuum, exhaust, oil or coolant leaks
develop, indicating a need for gasket or seal
replacement, the repairs can generally be
made with the engine in the vehicle. The
intake and exhaust manifold gaskets, oil pan
gasket, camshaft and crankshaft oil seals
and cylinder head gasket are all accessible
with the engine in place.
Exterior engine components, such as
the intake and exhaust manifolds, the oil pan,
the oil pump, the water pump, the starter
motor, the alternator, the distributor and the
fuel system components can be removed for
repair with the engine in place.
Since the camshaft(s) and cylinder head
can be removed without pulling the engine,
valve component servicing can also be
accomplished with the engine in the vehicle.
Replacement of the timing belt and sprockets
is also possible with the engine in the vehicle.
In extreme cases caused by a lack of
necessary equipment, repair or replacement
of piston rings, pistons, connecting rods and
rod bearings is possible with the engine in the
vehicle. However, this practice is not recom-
mended because of the cleaning and prepa-
ration work that must be done to the compo-
nents involved.
3
Valve cover - removal and
installation
Removal
Refer to illustrations 3.6a and 3.6b
1
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
2
Remove the ignition coil pack from the
valve cover (see Chapter 5).
3
Remove the spark plug wires (see Chap-
ter 1).
4
On 2.4L engines, disconnect the ground
strap from the valve cover.
5
Clearly label and then disconnect any
emission hoses and electrical cables which
connect to or cross over the valve cover.
6
Remove the valve cover bolts and lift the
cover off (see illustrations). If the cover
sticks to the cylinder head, tap on it with a
soft-face hammer or place a wood block
against the cover and tap on the wood with a
hammer. Caution: If you have to pry between
the valve cover and the cylinder head, be
extremely careful not to gouge or nick the
gasket surfaces of either part. A leak could
develop after reassembly.
7
Remove the valve cover gasket, 1/2
round seal (2.4L engines) and spark plug tube
seals. Thoroughly clean the valve cover and
remove all traces of old gasket material. Gas-
ket removal solvents are available from auto
parts stores and may prove helpful. After
cleaning the surfaces, degrease them with a
rag soaked in lacquer thinner or acetone.
Installation
Refer to illustrations 3.8 and 3.9
8
Install the new spark plug tube seals
(see illustration).
9
Install a new gasket on the cover,
using RTV sealant to hold it in place (see
illustration).
3.8 Install new spark plug tube seals
and make sure they are properly
seated in the cover
Chapter 2 Part A Four-cylinder engines
2A-5
3.9 Apply a light coat of RTV sealant onto the cover sealing
surfaces and install the new gasket (arrow)
3.16 After applying a small amount of Loctite No. 271 (or
equivalent) to the lower end of the tube(s) (arrows), install
it and carefully tap the tube into place until its fully seated
in the cylinder head (2.0L engine only)
2A
10
On 2.4L engines, install the half-round
seal, apply anaerobic RTV sealant to the
camshaft cap corners and at the top edges of
the half-round seal.
11
Place the cover on the engine and install
the cover bolts. Tighten the valve cover bolts
in three steps to the torque listed in this
Chapter's Specifications using a criss-cross
pattern, starting in the middle of the cover
and working outwards.
12
The remaining installation steps are the
reverse of removal. When installation is com-
plete, start the engine and check for oil leaks.
Spark plug tube replacement
(2.0L engine only)
Refer to illustration 3.16
13
Remove the valve cover (see above).
14
Grasp spark plug tube with locking pli-
ers, carefully twist back and forth and remove
the tube from cylinder head.
15
Clean the locking agent from the tube
end and the receptacle in cylinder head with
solvent and dry.
16
Apply approximately 1/8 inch wide strip
of Loctite sealer No. 271, or equivalent,
around the lower end of the tube and install
the tube into the cylinder head. Carefully tap
the tube into the receptacle with a soft face
mallet or wood block. Tap the tube in until it
is fully seated in the cylinder head (see illus-
tration).
17
Allow the Loctite to cure according to
the manufacturer's instructions.
18 Install the valve cover (see above).
4
Intake manifold - removal,
inspection and installation
Warning: Allow the engine to cool completely
before beginning this procedure.
Removal
Refer to illustrations 4.4a, 4.4b, 4.8, 4.11a
and 4.1lb
1
Relieve the fuel system pressure (see
Chapter 4).
2
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
3
Remove the air cleaner assembly (see
Chapter 4).
4
Clearly label and disconnect all vacuum
hoses, wires, brackets and emission hoses
which run to the fuel injection system, throttle
body and intake manifold (see illustrations).
5
Remove the fuel rail and injector assem-
bly (see Chapter 4).
6
Remove the throttle body (see Chap-
ter 4).
7
Remove the transaxle-to-throttle body
support bracket fasteners and loosen (only)
the fastener on the transaxle side. Be sure to
disconnect any electrical connections that
are fastened to the support bracket before
trying to move the parts out of the way.
8
Remove the EGR tube (see illustration).
9
On 2.0L engines, remove the water inlet
tube support-to-intake manifold fastener.
10
On 2.4L engines, remove the intake
manifold support bracket located on the
driver's side of the manifold.
4.4b Disconnect the power brake booster
vacuum hose from the intake manifold
(2.0L engine shown)
4.4a Disconnect the PCV valve hose
from the intake manifold fitting
(2.0L engine shown)
4.8 Remove the mounting bolts from the
EGR tube (arrows) at the intake manifold
and EGR valve (shown) and remove
the tube
2A-6
Chapter 2 Part A Four-cylinder engines
4.11a Remove the intake manifold mounting bolts in a
criss-cross pattern .. .
4.l lb . . . then remove the intake manifold from the cylinder head
11
Unbolt the intake manifold and remove it
from the engine (see illustrations). If it
sticks, lightly tap the manifold with a soft-
face hammer or carefully pry it from the head.
Caution: On 2.4L engines, do not pry
between gasket sealing surfaces or tap on
any fuel injector boss. On 2.0L engines, the
intake manifold is made of plastic. Although
it's pretty strong, it's not very impact resistant
so use caution when tapping on it.
Inspection
Refer to illustration 4.13
12
On 2.4L engines, remove intake mani-
fold gasket by carefully scraping all traces of
gasket material from both the cylinder head
and the intake manifold. Caution: The cylin-
der head and intake manifold are made of alu-
minum and are easily nicked or gouged. Don't
damage the gasket surfaces or a leak may
result after the work is complete. Gasket
removal solvents are available from auto parts
stores and may prove helpful.
13
On 2.0L engines, remove the 0-ring seal
gaskets on the intake and throttle body ports
(see illustration). Caution: The intake mani-
fold is made of plastic and can be easily dam -
aged, don't scrape too hard when removing
any dirt or residue. Examine the intake mani-
fold for evidence of cracks and other dam-
age. Replace if any are found.
14
Using a straightedge and feeler gauge,
check the intake manifold mating surface for
warpage. Check the intake manifold surface
on the cylinder head also. If the warpage on
any surface exceeds the limits listed in this
Chapter's Specifications, the intake manifold
and/or cylinder head must be replaced or
resurfaced by an automotive machine shop.
Installation
Refer to illustrations 4.15a and 4.15b
Note: On 2.0L engines whenever the intake
manifold is removed, the manufacturer rec-
ommends using new bolts and washers for
installation.
15 Install the intake manifold, using a new
gasket or 0-rings as applicable. Tighten the
bolts in three stages, in the sequence shown
(see illustrations), to the torque listed in this
Chapter's Specifications.
16
The remaining installation steps are the
reverse of removal.
5
Exhaust manifold - removal,
inspection and installation
Warning: Allow the engine to cool completely
before beginning this procedure.
Removal
Refer to illustrations 5.3, 5.4, 5.5 and 5.6
1
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
2
Set the parking brake and block the rear
wheels. Raise the front of the vehicle and
support it securely on jackstands.
3
Working under the vehicle, apply pene-
trating oil to the exhaust pipe-to-manifold
fasteners to make removal easier. Remove
the fasteners securing the exhaust pipe to the
exhaust manifold and separate them (see
illustration). Remove the seal ring (2.0L) or
gasket (2.4L) as applicable.
4
Disconnect the wiring harness from the
upstream oxygen sensor (see illustration).
5
Remove the bolts that secure the heat
shield to the exhaust manifold and remove
the heat shield (see illustration).
4.13 On 2.0L engines, remove the 0-ring seal gaskets (arrows) on
the throttle body and intake ports
4.15a Intake manifold bolt tightening sequence (2.0L engine)
Chapter
2
Part
A Four-cylinder engines
2A-7
4.15b Intake manifold bolt tightening sequence (2.4L engine)
5.3 Using a box wrench on the nuts and a socket on the bolt,
remove the shoulder bolts, springs and nuts securing
the exhaust pipe to the exhaust manifold
5.4 Follow the harness from the upstream
oxygen sensor (arrow) and disconnect
it at the connector
6
Remove the exhaust manifold mounting
bolts and remove the exhaust manifold (see
illustration). Note: The exhaust pipe may have
to be removed from the vehicle to facilitate
manifold removal (see Chapter 4 if necessary).
Inspection
7
Using a wire brush, clean the exhaust
manifold bolts, replacing any that exhibit
thread damage.
8
Using a scraper, remove all traces of
gasket material from the exhaust flange mat-
ing surfaces and inspect them for wear and
cracks. Caution: When removing gasket
material, be very careful not to scratch or
gouge the sealing surface. Any damage to the
surface may a leak after reassembly. Gasket
removal solvents are available from auto parts
stores and may prove helpful.
9
Using a straightedge and feeler gauge,
check the exhaust manifold-to-cylinder head
mating surface for warpage. Check the sur-
face on the cylinder head also. If the warpage
exceeds the limits listed in this Chapter's
Specifications, the exhaust manifold and/or
cylinder head must be replaced or resurfaced
by an automotive machine shop.
Installation
10
Apply Loctite No. 271 to the mounting
bolt threads prior to installation.
11
Install the new gasket (use no sealant),
manifold and bolts. Tighten the bolts in three
stages, working from the center out, to the
torque listed in this Chapter's Specifications.
12
The remaining installation steps are the
reverse of removal. Install a new gasket or
seal ring (as applicable) between the exhaust
manifold and exhaust pipe.
13
Run the engine and check for exhaust
leaks.
6
Timing belt - removal, inspection
and installation
Caution: If the timing belt failed with the
engine operating, damage to the valves may
have occurred. Perform an engine compres-
sion check after belt replacement to deter-
mine if any valve damage is present.
Removal
Refer to illustrations 6.4, 6.5, 6.8a, 6.8b, 6.9a,
6.9b, 6.11 and 6.12
Caution: Do not turn the crankshaft or
camshaft(s) after the timing belt has been
removed,
as
this will damage the valves from
contact with the pistons. Do not try to turn
the crankshaft with the camshaft(s) sprocket
bolt(s) and do not rotate the crankshaft coun-
terclockwise.
2A
5.5 Remove the exhaust manifold heat shield mounting bolts
(arrows) and remove the heat shield
5.6 Remove the exhaust manifold mounting bolts (arrows) and
separate the exhaust manifold from the cylinder head
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