Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 490
(7) Install crankshaft sprocket, using Special Tool
6792 (Fig. 102).
(8) Install oil pick-up tube and oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL
PAN
-
INSTALLA-
TION).
(9) Install timing belt rear cover and camshaft
sprockets (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - INSTALLATION).
(10) Install
the
timing
belt
tensioner
pulley
bracket (Refer to 9 - ENGINE/VALVE TIMING/
TMNG
BELT/CHAIN
TENSIONER&PULLEY
-
INSTALLATION).
(11) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(12) Install the front timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(13) Install crankshaft vibration damper (Refer to
9
-
ENGINE/ENGINE
BLOCK/VIBRATION
DAMPER - INSTALLATION).
(14) Fill engine crankcase with proper oil to cor-
rect level.
(15) Connect negative cable to battery.
INTAKE MANIFOLD
DIAGNOSIS AND TESTING
INTAKE MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM’S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING SYSTEM COMPONENTS. SER-
VICE VEHICLES IN WELL VENTILATED AREAS AND
AVOID IGNITION SOURCES. NEVER SMOKE WHILE
SERVICING THE VEHICLE.
(1) Perform fuel system pressure release procedure
before attempting any repairs. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
(2) Disconnect negative battery cable.
(3) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
Fig. 101 Front Crankshaft Seal—Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780–1
4 - INSTALLER
Fig. 102 Crankshaft Sprocket—Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
JR
ENGINE 2.0L DOHC
9 - 63
OIL PUMP (Continued)
(4) Remove throttle body air inlet hose and air
cleaner housing assembly.
(5) Remove throttle and speed control cables from
throttle lever and bracket.
(6) Remove EGR tube (if equipped).
(7) Remove engine oil dipstick and tube from
engine block. Plug hole in block to prevent debris or
fluid from entering engine crankcase.
(8) Disconnect
necessary
vacuum
hoses
from
intake manifold.
(9) Disconnect the fuel supply line quick connect at
the fuel rail assembly.
WARNING: WRAP SHOP TOWELS AROUND HOSE
TO CATCH ANY GASOLINE SPILLAGE.
(10) Remove fastener holding fuel rail bracket to
side of cylinder head.
(11) Disconnect the following electrical connectors:
• Fuel Injectors
• Knock Sensor
• ECT Sensor
• IAC
• TPS
• MAP Sensor
• A/C Pressure Sensor
• A/C Compressor Clutch
• Generator
(12) Reposition wiring harness.
(13) Remove fuel rail support bracket (Fig. 103).
(14) Remove fuel rail.
(15) Remove coolant outlet connector (Refer to 7 -
COOLING/ENGINE/COOLANT OUTLET HOUSING
- REMOVAL).
(16) Remove intake manifold fasteners. Remove
intake manifold.
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
(1) Inspect
manifold
for
cracks,
distortion,
or
mounting surface warpage. Replace manifold if nec-
essary.
(2) Inspect manifold for gasket surface damage or
excessive swelling. Replace manifold if necessary.
INSTALLATION
(1) Install new intake manifold and gasket. Grad-
ually tighten fasteners to 28 N·m (250 in. lbs.) in
sequence shown in (Fig. 104).
(2) Install coolant outlet connector (Refer to 7 -
COOLING/ENGINE/COOLANT OUTLET HOUSING
- INSTALLATION).
(3) Install fuel rail.
(4) Install fuel rail support bracket (Fig. 103).
(5) Connect previously disconnected electrical con-
nectors.
(6) Install fastener holding fuel rail bracket to side
of cylinder head.
(7) Inspect quick connect fittings for damage,
replace if necessary. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(8) Connect vacuum hoses to intake manifold.
(9) Install engine oil dipstick and tube.
(10) Install EGR tube (if equipped).
(11) Install throttle and speed control cables to
bracket. Connect cables to the throttle lever.
(12) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(13) Connect negative battery cable.
(14) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove complete exhaust system (Refer to 11 -
EXHAUST SYSTEM - REMOVAL).
(4) Remove rear engine mount and transaxle
bracket.
Fig. 103 Fuel Rail Support Bracket
9 - 64
ENGINE 2.0L DOHC
JR
INTAKE MANIFOLD (Continued)
(5) Remove exhaust manifold heat shield (Fig.
105).
(6) Disconnect oxygen sensor electrical connector.
(7) Remove exhaust manifold retaining fasteners
and remove exhaust manifold.
(8) Remove and discard manifold gasket.
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Install new exhaust manifold gasket. DO NOT
APPLY SEALER.
(2) Position exhaust manifold in place. Gradually
tighten fasteners in sequence shown in (Fig. 106) to
23 N·m (200 in. lbs.).
(3) Install exhaust manifold heat shield.
(4) Connect oxygen sensor electrical connector.
(5) Install
rear
engine
mount
and
transaxle
bracket.
(6) Install
exhaust
system
(Refer
to
11
-
EXHAUST SYSTEM - INSTALLATION). Tighten fas-
teners to 28 N·m (250 in. lbs.).
(7) Lower vehicle.
(8) Connect negative battery cable.
Fig. 104 Intake Manifold Tightening Sequence
Fig. 105 Exhaust Manifold Heat Shield Bolts
1 - BOLTS
Fig. 106 Exhaust Manifold Tightening Sequence
JR
ENGINE 2.0L DOHC
9 - 65
EXHAUST MANIFOLD (Continued)
VALVE TIMING
STANDARD PROCEDURE
VALVE TIMING VERIFICATION
(1) Remove number one spark plug.
(2) Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
(3) Remove the access plug from the front timing
belt cover.
(4) Check the timing marks on the camshaft
sprockets, they should align with each other (Fig.
107).
TIMING BELT COVER(S)
REMOVAL
FRONT COVER
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove right front wheel and accessory drive
belt splash shield.
(4) Remove the accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(5) Remove the crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(6) Remove accessory drive belt automatic ten-
sioner.
(7) Disconnect generator connectors. Remove gen-
erator and bracket.
(8) Lower vehicle.
(9) Position
a
jack
under
engine.
Raise
jack
enough to support engine weight.
(10) Remove the right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
REMOVAL).
(11) Remove front engine mount bracket (Fig. 108).
(12) Remove the front timing belt cover (Fig. 108).
REAR COVER
(1) Remove front timing belt cover.
CAUTION: Camshaft(s) or crankshaft should not be
rotated after timing belt is removed. Damage to
valve components may occur. Always align timing
marks before removing timing belt.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove timing belt tensioner assembly (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT
TENSIONER & PULLEY - REMOVAL).
(4) Remove timing belt idler pulley.
(5) Hold camshaft sprockets with Special Tools
C-4687 and Adaptor C-4687-1 (Fig. 109), while
removing attaching bolts.
(6) Remove camshaft sprockets.
(7) Remove rear timing belt cover attaching bolts.
(8) Remove rear cover.
Fig. 107 Camshaft Timing Check
1 - CAMSHAFT TIMING MARKS SHOULD LINE UP
Fig. 108 Front Timing Belt Cover
1 - FRONT TIMING BELT COVER FASTENERS
2 - ACCESS PLUG
3 - FRONT ENGINE MOUNT BRACKET
4 - FASTENERS
9 - 66
ENGINE 2.0L DOHC
JR
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