Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual — part 8
2A-8
Chapter 2 Part A Four-cylinder engines
1
Position the number one piston at Top
Dead Center (see Chapter 2C).
2
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
3
Remove the drivebelts (see Chapter 1).
4
Loosen the large bolt in the center of the
crankshaft damper pulley. It might be very
tight, to break it loose insert a large screw-
driver or bar through the opening in the pulley
to keep the pulley stationary and loosen the
bolt with a socket and breaker bar (see illus-
tration).
5
Install a 3-jaw puller onto the damper
pulley and remove the pulley from the
crankshaft (see illustration). Use the proper
insert to keep the puller from damaging the
crankshaft bolt threads. If the pulley is diffi-
cult to remove, tap the center bolt of the
puller with a brass mallet to break it loose.
Caution: Do not use a puller that has jaws
which grip the outer diameter of the damper
as the damper and hub may separate. Use
only the type shown in the illustration.
6
After removing the crankshaft pulley,
reinstall the crankshaft bolt using an appro-
priate spacer (this will enable you to turn the
crankshaft later).
7
Remove the right (passenger side)
engine mount and the mounting bracket from
the engine (see Section 17). Note: Make sure
the engine is supported with a floor jack
placed under the oil pan. Place a wood block
on the jack head to prevent the floor jack from
denting or damaging the oil pan.
8
Remove the timing belt outer cover(s)
(see illustrations).
9
Make sure the camshaft sprocket(s) and
crankshaft timing marks align before remov -
6.4 Insert a large screwdriver or bar
through the opening in the crankshaft
pulley and wedge it against the engine
block, then loosen the bolt with a
socket and breaker bar
ing the timing belt (see illustrations). If nec-
essary, align the timing marks by rotating the
crankshaft - clockwise only! Note: If you plan
to reuse the timing belt, paint an arrow on it
to indicate the direction of rotation (clock-
wise).
10
Two different types of timing belt ten-
sioners were incorporated on these engines,
hydraulic and mechanical. The hydraulic
tensioner is easily recognizable by the sealed
hydraulic unit which maintains constant pres-
sure on the timing belt tensioner pulley. The
mechanical type has a built-in spring inside
the pulley which supplies clockwise tension
to the belt.
11
On engines equipped with a hydraulic
tensioner, loosen, then remove the timing
6.5 Install a 3-jaw puller onto the damper
pulley, position the center post of the
puller on the crankshaft end (use the
proper insert to keep from damaging the
crankshaft threads), and remove the
pulley from the crankshaft
belt tensioner mounting bolts (see illustra-
tion) and remove the tensioner. Note: The
tensioner piston will extend when the assem-
bly is removed.
12
On engines equipped with a mechanical
tensioner, insert an 8 mm (2.0L engine)
or 6 mm (2.4L engine) Allen wrench in the
hexagon fitting in the tensioner pulley. Insert
the long end of a 3 mm Allen wrench (or 1/8
inch drill bit) into the small hole on the pulley.
While applying light pressure to the Allen
wrench or drill bit, rotate the tensioner pulley
counterclockwise until the Allen wrench or
drill bit slides into the locking hole (see illus-
tration).
UPPER TIMING BOLT
COVER FASTENERS
1
LOWER TIMING
BELT COVER
FASTENERS
- INDICATES RETAINING
CLIP LOCATION
6.8a Remove the two lower bolts and upper clip retaining the
ti ming belt outer cover to the engine (2.0L SOHC engine)
6.8b Timing belt outer cover fastener locations (2.4L engine)
Chapter 2 Part A Four-cylinder engines
2A-9
6.9a Before removing the timing belt, make sure the camshaft
sprocket and crankshaft timing marks align with their respective
marks - rotate the engine (clockwise only as viewed from the
crankshaft end) as required to align both sets of timing
marks (2.0L engine timing marks)
CAMSHAFT TIMING-MARKS
6.9b 2.4L engine timing marks - The crankshaft sprocket timing
mark is on the trailing edge of the sprocket tooth
TRAILING
EDGE OF
SPROCKET
TOOTH
CRANKSHAFT TDCMARKS
2A
13
Carefully slip the timing belt off the
sprockets and set it aside. If you plan to
reuse the timing belt, store it in a plastic bag -
do not allow the belt to come in contact with
any type of oil or water as this will greatly
shorten belt life.
14 If it's necessary to remove the camshaft
sprocket(s), and/or timing belt rear cover (for
camshaft seal replacement, see Section 8).
Inspection
Refer to illustration 6.18
15 Inspect the crankshaft front oil seal for
leaks and replace it if necessary (see Sec-
tion 7)..
16 Inspect the water pump for evidence of
leakage (usually indicated by a trail of wet or
dried coolant). Check the pulley for excessive
radial play and bearing roughness. Replace if
necessary (see Chapter 3).
17
Rotate the tensioner pulley and idler pul-
ley (2.4L engines) by hand and move them
side-to-side to detect bearing roughness and
excess play. Visually inspect all timing belt
sprockets for any signs of damage or wear.
Replace parts as necessary.
18 Inspect the timing belt for cracks, sepa-
ration, wear, missing teeth and oil contamina-
tion (see illustration). Replace the belt if it's
6.11 Loosen, then remove the timing belt hydraulic tensioner
mounting bolts (arrows) and remove the tensioner
(2.0L engine shown)
ALLEN
WRENCH
6.12 To relieve the timing belt tension on mechanical type
tensioners, place the appropriate size Allen wrench in the pulley
and apply torque in a counterclockwise direction until the
retaining pin holes align and insert a 3mm Allen wrench or
1/8 inch drill bit to hold the pulley in place
2A-10
Chapter 2 Part A Four-cylinder engines
in questionable condition or the engine
mileage is close to that referenced in the
Maintenance Schedule (see Chapter 1).
19 If equipped, check the hydraulic ten-
sioner for leaks or any other obvious damage,
replace if necessary.
Installation
2.0L engine
Refer to illustrations 6.21a, 6.2 lb and 6.21c
20
Confirm that the camshaft sprocket tim-
ing marks are aligned (see illustration 6.9a).
Reposition as required.
21
Position the crankshaft timing belt
sprocket as follows (see illustrations):
a) Initially align the TDC mark on the
sprocket with the arrow on the oil pump
housing.
b) Then back it off counterclockwise 3
teeth BTDC.
c) Rotate the crankshaft sprocket clock-
wise to 1/2-tooth before the arrow mark
on the oil pump housing.
22 Install the timing belt as follows; first
place the belt onto the crankshaft sprocket,
maintaining tension on the belt, wrap it
around the water pump sprocket, camshaft
sprocket and the tensioner pulley.
23
To take the slack out of the timing belt,
rotate the crankshaft timing sprocket clock-
wise to align the timing marks (TDC), make
sure the camshaft sprocket timing marks
remain aligned.
2.4L engine
Refer to illustration 6.25
24
Confirm that the timing marks on the
camshaft sprockets are aligned (see illustra-
tion 6.9b).
25
Rotate the exhaust camshaft sprocket
clockwise so the timing mark is 1/2 tooth
below the intake camshaft timing mark as
shown (see illustration).
26
Next, align the crankshaft sprocket tim-
ing mark with the arrow mark on the oil pump
housing (see illustration 6.9b).
6.18 Carefully inspect the timing belt -
bending it backwards will often make
wear or damage more apparent
27 Install the timing belt as follows; first
place the belt onto the crankshaft sprocket,
maintaining tension on the belt, wrap it
around the water pump sprocket, idler pulley,
camshaft sprockets and the tensioner pulley.
To take up the belt slack, rotate the exhaust
camshaft counterclockwise until the timing
marks on both sprockets align.
Engines with a mechanical
tensioner
28
On engines equipped with a mechanical
tensioner, pull the retaining pin from the ten-
sioner pulley.
29
Using the bolt in the center of the
crankshaft sprocket, turn the crankshaft
clockwise two complete revolutions. Cau-
tion: If you feel resistance while turning the
crankshaft - STOP, the valves may be hitting
the pistons from incorrect valve timing. Stop
and re-check the valve timing. Note: The
camshaft and crankshaft sprocket marks will
align every two revolutions of the crankshaft.
30
Recheck the alignment of the timing
marks (see illustrations 6.9a and 6.9b). If
the marks do not align properly, loosen the
tensioner, slip the belt off the camshaft
6.21a On 2.0L engines, use a box-end
wrench or socket to rotate the crankshaft
ti ming sprocket until the TDC mark on the
sprocket is aligned with the arrow on the
oil pump housing (arrow) .. .
6.21b . . . then back it off
counterclockwise 3 teeth BTDC (arrows)
sprocket, realign the marks, reinstall the belt,
and check the alignment again.
31
The remaining installation steps are the
reverse of removal. Tighten the crankshaft
pulley bolt to the torque listed in this Chap-
ter's Specifications. Start the engine and
road test the vehicle.
CAMSHAFT
SPROCKET EXHAUST
CAMSHAFT
SPROCKET INTAKE
6.21c Rotate the crankshaft timing sprocket clockwise
to 1/2-tooth BTDC (arrows)
6.25 Before installing the timing belt, rotate the exhaust
camshaft sprocket clockwise so the timing mark is 1/2 tooth
below the timing mark on the intake camshaft sprocket
Chapter 2 Part A Four-cylinder engines
2A-11
6.32a The hydraulic tensioner piston (arrow) must be compressed
into the tensioner housing prior to installation
6.32b Place the tensioner in a vise with the hole (arrow) facing up.
Compress the piston with the vise and insert a 5/64 inch Allen
wrench or drill bit through the hole to keep the piston
retracted for installation
2A
Engines with a hydraulic tensioner
Refer to illustrations 6.32a, 6.32b and 6.34
32
On engines equipped with a hydraulic
tensioner, the piston must be compressed
into the tensioner housing prior to installation.
Place the tensioner in a vise with the pin
holes facing up. Slowly compress the ten-
sioner, then install a 5/64-inch Allen wrench
or drill bit through the body to retain the pis-
ton in this position (see illustrations).
Remove the tensioner from the vise.
33 Install the tensioner assembly - except
don't tighten the bolts at this time.
34
Have an assistant place a torque
wrench on the center bolt of the tensioner
pulley and apply 250 in-lbs of torque in a
clockwise direction. With the torque applied
to the tensioner pulley, move the tensioner up
against the tensioner pulley bracket and
tighten the tensioner bolts to the torque listed
in this Chapter's Specifications (see illustra-
tion). Remove the torque wrench.
35
Pull the Allen wrench or drill bit from the
tensioner. The timing belt tension is correct
when the pin can be withdrawn and rein-
serted easily. Verify that the timing marks on
the camshaft sprocket(s) and crankshaft
sprocket are still aligned at TDC.
36
Using the bolt in the center of the
crankshaft sprocket, turn the crankshaft
clockwise two complete revolutions. Cau-
tion: If you feel resistance while turning the
crankshaft - STOP, the valves may be hitting
the pistons from incorrect valve timing. Stop
and re-check the valve timing. Note: The
camshaft and crankshaft sprocket marks will
align every two revolutions of the crankshaft.
Recheck the alignment of the timing marks
(see illustrations 6.9a and 6.9b). If the
marks do not align properly, loosen the ten-
sioner, slip the belt off the camshaft
sprocket(s), realign the marks, reinstall the
belt, and check the alignment again.
37
After crankshaft rotation, recheck the
ti ming belt tension by inserting the retaining
pin (5/64-inch Allen wrench or drill bit) back
into the tensioner. If the retaining pin cannot
be inserted and withdrawn freely, readjust the
ti ming belt tension and repeat Steps 34
through 37.
38
The remaining installation steps are the
reverse of removal. Tighten the crankshaft
pulley bolt to the torque listed in this Chap-
ter's Specifications.
39
Start the engine and road test the vehi-
cle.
7
Crankshaft front oil seal -
replacement
Refer to illustrations 7.2, 7.3, 7.5 and 7.6
Caution: Do not rotate the camshaft(s) or
crankshaft when the timing belt is removed or
damage to the engine may occur.
1
Remove the timing belt (see Section 6).
2
Remove the crankshaft timing belt
sprocket from the crankshaft with a bolt-type
gear puller (see illustration). Remove the
Woodruff key from the crankshaft keyway.
LOCKING PIN
INSTALLED
INTO THE
TENSIONER
6.34 Using a torque wrench on the tensioner pulley bolt, apply 250
inch-lbs of torque as shown, move the hydraulic tensioner up
against the tensioner pulley bracket and tighten the tensioner
mounting bolts to the torque listed in this Chapter's Specifications
7.2 Attach a bolt-type gear puller to the crankshaft sprocket and
remove the sprocket from the crankshaft
2A-12
Chapter 2 Part A Four-cylinder engines
7.3 Using a screwdriver, very carefully pry
the front crankshaft seal from it's bore
8.4a Remove the hydraulic tensioner
pulley/plate assembly mounting
bolts (arrows) .. .
3
Wrap the tip of a small screwdriver with
tape. Working from below the right inner
fender, use the screwdriver to carefully pry
the seal out of its bore (see illustration).
Take care to prevent damaging the oil pump
assembly, the crankshaft and the seal bore.
4
Thoroughly clean and inspect the seal
bore and sealing surface on the crankshaft.
Minor imperfections can be removed with
emery cloth. If there is a groove worn in the
crankshaft sealing surface (from contact with
8.8 Carefully pry the camshaft seal out of
the bore - DO NOT nick or scratch the
camshaft or seal bore
7.5 Lubricate the new front crankshaft
seal with engine oil and using a hammer
and socket, drive the seal into the bore
until it's flush with the oil pump housing
8.4b . . . and then remove the pulley and
bracket assembly (2.0L engine)
the seal), installing a new seal will probably
not stop the leak.
5
Lubricate the new seal with engine oil
and using a hammer and the appropriate size
socket, drive the seal into the bore until it's
flush with the oil pump housing. (see illustra-
tion).
6
Install the Woodruff key and the
crankshaft timing belt sprocket with the word
FRONT facing out onto the crankshaft (see
illustration).
7
The remaining installation steps are the
reverse of removal. Tighten the crankshaft
pulley bolt to the torque listed in this Chap-
ter's Specifications.
8
Start the engine and check for oil leaks.
8
Camshaft oil seal - replacement
Refer to illustrations 8.4a, 8.4b, 8.7, 8.8,
8.10a, 8.10b and 8.12
Caution: Do not rotate the camshaft(s) or
crankshaft when the timing belt is removed or
damage to the engine may occur.
1
Remove the timing belt (see Section 6).
2
Rotate the crankshaft counterclockwise
until the crankshaft sprocket is three teeth
BTDC (see illustration 6.21b). This will pre-
vent engine damage if the camshaft sprocket
is inadvertently rotated during sprocket bolt
7.6 Position the crankshaft sprocket with
the word FRONT (arrow) facing out and
install it onto the crankshaft
8.7 Remove the rear timing belt cover
removal.
3
While holding the camshaft sprocket,
remove the camshaft sprocket bolt. Then,
using two large screwdrivers, lever the
sprocket off the camshaft. Note: To hold the
camshaft/sprocket while loosening the bolt, a
strap-type damper/pulley holder tool is rec-
ommended and is available at most auto
parts stores. If the strap wrench is unavail-
able, remove the valve cover to access the
wrenching flats on the camshaft (2.4L
engines only).
4
On 2.0L engines, remove the 2 bolts
securing the tensioner pulley bracket to the
engine block and remove the pulley and
bracket assembly (see illustrations). Do not
attempt to loosen the center bolt on the pul-
ley or the pulley pivot bolt, remove the pulley
and bracket together.
5
On 2.4L engines, remove the idler pul-
ley.
6
On 2.0L engines equipped with a
hydraulic timing belt tensioner, remove the
tensioner pulley.
7
Remove the bolts securing the rear
cover to the engine block and cylinder head.
Remove the rear cover (see illustration).
8
Carefully pry out the camshaft oil seal
using a small screwdriver (see illustration).
Don't scratch the bore or damage the
camshaft in the process (if the camshaft is
damaged, the new seal will end up leaking).
Chapter 2 Part A Four-cylinder engines
2A-13
8.10a Using a hammer and socket, gently
tap the new seal into place with the
spring side facing inward
9
Clean the bore and coat the outer edge
of
the new seal with engine oil or multi-pur-
pose grease. Also lubricate the seal lip.
10
Using a socket with an outside diameter
slightly smaller than the outside diameter of
the seal and a hammer (see illustration),
carefully drive the new seal into the cylinder
head until it's flush with the face of the cylin-
der head. If a socket isn't available, a short
section of pipe will also work. Note: If engine
location makes it difficult to use a hammer to
install the camshaft seal, fabricate a seal
installation tool from a piece of pipe cut to the
appropriate length, a bolt and a large washer
(see illustration). Place the section of pipe
over the seal and thread the bolt into the
camshaft. The seal can now be pressed into
the bore by tightening the bolt.
11
Install the rear timing belt cover, ten-
sioner pulley/bracket, idler pulley and ten-
sioner pulley as applicable.
12 Install the camshaft sprocket, aligning
the pin in the camshaft with the hole in the
sprocket (see illustration). Use an appropri-
ate tool to hold the camshaft sprocket while
tightening the sprocket bolt to the torque
li sted in this Chapter's Specifications.
13
Reinstall the timing belt (see Section 6).
14
Run the engine and check for oil leaks.
8.10b If space is limited and you can't use
a hammer and socket to install the seal, a
seal installer can be made from a section
of pipe (of appropriate diameter), a bolt
and washer. Place the pipe over the
seal and press it into place by
tightening the bolt
9
Rocker arm and hydraulic valve
lash adjuster - removal,
inspection and installation
Removal
2.0L engine
Refer to illustration 9.6
1
Position the number one piston at Top
Dead Center (see Chapter 2C).
2
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
3
Remove the valve cover (see Section 3).
4
Prior to removing the rocker arm shafts,
mark the front shaft (intake manifold side) as
the intake rocker arm shaft and the rear shaft
(exhaust manifold side) as the exhaust. Cau-
tion: Do not interchange the rocker arms onto
a different shaft as this could lead to prema-
ture wear.
5
Loosen the rocker arm shaft bolts 1/4 -
8.12 When installing a camshaft sprocket,
make sure the pin in the camshaft is
aligned with the hole in the
sprocket (arrows)
turn at a time each, until the valve spring
pressure is relieved, in the reverse order of
the tightening sequence (see illustration
9.20). Completely loosen the bolts, but do
not remove them, since leaving them in place
will prevent the assembly from falling apart
when it is lifted off the cylinder head.
6
Lift the rocker arms and shaft assem-
blies from the cylinder head and set them on
the workbench (see illustration). Note: The
hydraulic valve lash adjusters may become
dislodged from the rocker arms during shaft
removal. If required, secure the adjusters in
place using electrical tape.
7
Disassemble the rocker arm shaft com-
ponents. Caution: Before disassembly, mark
the rocker arm shafts, rocker arms, shaft
retainers and plastic shaft spacers (intake
only) so all the parts can be reassembled in
their original locations. To keep the rocker
arms and related parts in order, it's a good
idea to remove them and put them onto two
lengths of wire (such as unbent coat hangers)
in the same order as they're removed, mark-
ing each wire (which simulates the rocker
shaft) as to which end would be the front of
the engine.
2A
9.6 Intake and exhaust rocker arms and shaft assemblies
(2.0L engine)
9.9 On 2.4L engines, once the camshafts have been removed, the
rocker arms and hydraulic valve lash adjusters (located below the
rocker arm can be removed) - be sure to keep the rocker arms
and lash adjusters in order so they can be returned
to their original locations
o
—
2A-14
Chapter 2 Part A
Four-cylinder engines
2.4L engine
Refer to illustration 9.9
8
Remove both camshafts (see Sec-
tion 10).
9
Once the camshafts have been
removed, the rocker arms (a.k.a. cam follow-
ers) can be lifted off (see illustration). Cau-
tion: Each rocker arm and valve lash adjuster
must be placed back in it's original location,
so mark them or place them in a marked con-
tainer (such as an egg carton or cupcake tray)
so they won't get mixed up.
10
Remove the rocker arms and hydraulic
valve lash adjusters from the cylinder head.
Inspection
2.0L engine
Refer to illustration 9.11
Note: The valve lash adjuster is an integral
part of each rocker arm and cannot be
replaced separately.
11
Visually check the rocker arms for wear
(see illustration). Replace them if evidence
of wear or damage is found.
12 Inspect each lash adjuster carefully for
signs of wear and damage, particularly on the
surface that contacts the valve tip. Since the
lash adjusters frequently become clogged,
we recommend replacing the rocker arm/lash
adjuster assembly if you're concerned about
their condition or if the engine is exhibiting
valve "tapping" noises.
13
Check all the rocker shaft components.
Look for worn or scored shafts, etc. and
replace any parts found to be damaged or
worn excessively.
2.4L engine
Refer to illustration 9.14
14
Visually check the rocker arm tip, roller
and lash adjuster pocket for wear (see illus-
tration). Replace them if evidence of wear or
damage is found.
15 Inspect each adjuster carefully for signs
of wear and damage, particularly on the ball
tip that contacts the rocker arm. Since the
lash adjusters frequently become clogged,
we recommend replacing them if you're con-
cerned about their condition or if the engine
is exhibiting valve "tapping" noises.
Installation
2.0L engine
Refer to illustrations 9.18, 9.19 and 9.20
16
Prior to installation, the lash adjusters
must be partially full of engine oil - indicated
by little or no plunger action when the
adjuster is depressed. If there's excessive
plunger travel, place the rocker arm assembly
into clean engine oil and pump the plunger
until the plunger travel is eliminated. Note: If
the plunger still travels within the rocker arm
when full of oil it's defective and the rocker
arm assembly must be replaced.
9.11 2.0L engine rocker arm/valve lash
adjuster assembly (intake rocker
arm shown)
1
Hydraulic valve lash adjuster
2
Rocker shaft bore
3
Roller
17
When assembling the rocker arms on
the shaft assembly, make sure they're rein-
stalled in their original locations.
18
On the intake rocker arm shaft, make
sure the plastic spacers are installed on the
shaft in the correct locations (see illustra-
tion).
19 Install the rocker arm assemblies with
the notch in each rocker arm shaft located at
the timing belt end of the engine and facing
UP (see illustration).
9.14 2.4L engine rocker arm
9.18 Intake rocker arm plastic spacer locations (arrows)
(2.0L engine)
TIP
9.20 Rocker arm shaft bolt tightening sequence (2.0L engine)
4
9.19 Both rocker arm shafts must be installed with the notches
(arrows) facing UP and at the timing belt end of the engine
Chapter 2 Part A
Four-cylinder engines
2A-15
REMOVE OUTSIDE BEARING CAPS FIRST
10.7 2.4L engine camshaft bearing cap location numbers - they
must be reinstalled in their original locations
10.8 Remove the outside bearing caps first, then loosen the
remaining bearing cap bolts in the sequence shown 1/4 turn at a
ti me until they can be unscrewed by hand (2.4L engine)
20
Tighten the rocker arm bolts in
sequence shown (see illustration) using 3
steps to reach the torque listed in this Chap-
ter's Specifications.
21
The remaining installation steps are the
reverse of removal. Run the engine and
check for oil leaks and proper operation.
22
When re-starting the engine after replac-
ing the rocker arm/lash adjusters, the
adjusters will normally make "tapping"
noises. After warm-up, slowly raise the speed
of the engine from idle to 3,000 rpm and back
to idle over a one minute period. If the
adjuster(s) do not become silent, replace the
defective rocker arm/lash adjuster assembly.
2.4L engine
23
Prior to installation, the lash adjusters
must be partially full of engine oil - indicated
by little or no plunger action when the
adjuster is depressed. If there's excessive
plunger travel, place the rocker arm assembly
into clean engine oil and pump the plunger
until the plunger travel is eliminated. Note: If
the plunger still travels within the rocker arm
when full of oil it's defective and the rocker
arm assembly must be replaced.
10.12 Measure the camshaft bearing
journal diameters with a micrometer and
compare the measurements to the
dimensions given in this Chapter's
Specifications
24 Install the hydraulic lash adjusters and
rocker arms back in their proper locations on
the cylinder head.
25 Install the camshafts (see Section 10).
26
When re-starting the engine after replac-
ing the rocker arm/lash adjusters, the
adjusters will normally make "tapping"
noises. After warm-up, slowly raise the speed
of the engine from idle to 3,000 rpm and back
to idle over a one minute period. If the
adjuster(s) do not become silent, replace the
defective lash adjuster assembly.
10 Camshaft(s) - removal,
inspection and installation
Removal
2.0L engine
Note: The camshaft cannot be removed with
the cylinder head installed in the vehicle.
1
Remove the cylinder head (see Sec-
tion 12).
2
Remove the camshaft position sensor
(see Chapter 6).
3
Carefully withdraw the camshaft from
the opening in the rear of the cylinder head.
Caution: Don't damage the camshaft lobes
or bearing journals during removal and instal-
lation through the opening in the cylinder
head.
4
Remove the camshaft front seal from
the cylinder head.
2.4L engine
Refer to illustrations 10.7 and 10.8
5
Remove the timing belt (see Section 6).
6
Remove the camshaft sprockets and the
rear timing belt cover (see section 8).
7
The camshaft bearing caps are identi-
fied with their numbered location in the cylin-
der head (see illustration).
8
Remove the outside bearing caps at
each end of the camshafts first. Remove the
remaining camshaft bearing caps, loosening
the bolts a little at a time to prevent distorting
the camshaft(s) by loosening the caps in the
sequence shown (see illustration). Once the
bearing caps have all been loosened enough
for removal, they may still be difficult to
remove. Using the bearing cap bolts for extra
leverage, move the cap back and forth to
loosen the cap from the cylinder head. If they
are still difficult to remove you can tap them
gently with a soft face mallet so they can be
lifted off. Caution: Store them in order so
they can be returned to their original loca-
tions, with the same side facing forward.
9
Carefully lift the camshafts out of the
cylinder head. Mark the camshafts INTAKE
and EXHAUST, they cannot be mixed-up.
10
Remove the front seal from each
camshaft. Note: Now is a good time to
inspect the rocker arms and lash adjusters
(see Section 9).
Inspection
Refer to illustration 10.12
11
Thoroughly clean the camshaft(s) and
the gasket surface. Visually inspect the
camshaft for wear and/or damage to the lobe
surfaces, bearing journals and seal contact
surfaces. Visually inspect the camshaft bear-
ing surfaces in the cylinder head and bearing
caps (2.4L engines) for scoring and other
damage.
12
Measure the camshaft bearing journal
diameters (see illustration). Measure the
inside diameter of the camshaft bearing sur-
faces in the cylinder head, using a telescop-
ing gauge (on 2.4L engines, temporarily
install the bearing caps). Subtract the journal
measurement from the bearing measurement
to obtain the camshaft bearing oil clearance.
Compare this clearance with the value listed
in this Chapter's Specifications. Replace
worn components as required.
13
Replace the camshaft if it fails any of the
above inspections. Note: If the lobes are
worn, replace the rocker arms and lash
adjusters along with the camshaft. Cylinder
head replacement may be necessary if the
camshaft bearing surfaces in the head are
damaged or excessively worn.
14
Clean and inspect the cylinder head as
described in Part C of this Chapter.
2A
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