Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 498
Balance Shaft Sprocket Installer 6052
Front Crankshaft Oil Seal Installer 6780
Cooling System Tester 7700
Combustion Leak Tester C-3685-A
DRB III
T
with PEP Module OT-CH6010A
Pressure Transducer CH7059
Cylinder Compression Pressure Adaptor 8116
JR
ENGINE 2.4L DOHC
9 - 95
ENGINE 2.4L DOHC (Continued)
AIR CLEANER ELEMENT
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect inlet air temperature sensor electri-
cal connector.
(3) Disconnect fresh air makeup hose from throttle
body air inlet hose.
(4) Disconnect PCV hose from intake manifold.
(5) Loosen hose clamp at throttle body air inlet
hose. Remove hose from throttle body.
(6) Push in on locking tabs to disengage air inlet
hose from air cleaner housing. Remove throttle body
air inlet hose and air cleaner element together.
(7) Separate air cleaner element from throttle body
air inlet hose (Fig. 7).
INSTALLATION
(1) Clean any debris from inside air cleaner hous-
ing.
(2) Install air cleaner element onto throttle body
air inlet hose.
(3) Install throttle body air inlet hose into air
cleaner housing. Push in on hose until an audible
“click” is heard from locking tabs.
(4) Install hose on throttle body. Tighten hose
clamp.
(5) Connect PCV hose to intake manifold.
(6) Connect fresh air makeup hose.
(7) Connect inlet air temperature sensor electrical
connector.
(8) Connect negative battery cable.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect inlet air temperature sensor electri-
cal connector.
(3) Disconnect fresh air makeup hose from throttle
body air inlet hose.
(4) Loosen hose clamp at throttle body air inlet
hose. Remove hose from throttle body (Fig. 8).
(5) Remove push pin securing air duct to upper
radiator support.
(6) Remove nut on bracket that holds air cleaner
housing.
(7) Pull air cleaner housing straight up off locating
pins (Fig. 8).
INSTALLATION
(1) Install air cleaner housing straight down on
locating pins (Fig. 8).
(2) Install nut on bracket that holds air cleaner
housing and tighten.
(3) Install push pin that secures air duct to upper
radiator support.
(4) Install throttle body air inlet hose to throttle
body. Tighten hose clamp.
(5) Connect fresh air makeup hose.
(6) Connect inlet air temperature sensor electrical
connector.
(7) Connect negative battery cable.
Fig. 7 Air Cleaner Housing 4cyl
Fig. 8 Air Cleaner Housing
9 - 96
ENGINE 2.4L DOHC
JR
CYLINDER HEAD
DESCRIPTION
There will be two different cylinder heads that will
be used on the 2.4L engine. One will used on federal
package engine and the other on PZEV (partially
zero emmision vehicle) used in California emmission
packages.
Both engines have a cross flow designed, alumi-
num cylinder head that contains dual over-head cam-
shafts with four valves per cylinder (Fig. 9). The
valves are arranged in two in-line banks. The intake
valves face toward the front of the vehicle. The
exhaust valves face the dash panel. The cylinder
head incorporates powdered metal valve guides and
seats. The cylinder head is sealed to the block using
a multi-layer steel head gasket and retaining bolts.
The PZEV head has passages drilled into the exhaust
ports for air injection (Fig. 10).
Integral oil galleries provide lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
DIAGNOSIS AND TESTING
CYLINDER HEAD GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
• Loss of engine power
• Engine misfiring
• Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
• Engine overheating
• Loss of coolant
• Excessive steam (white smoke) emitting from
exhaust
• Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50–70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
Fig. 9 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
Fig. 10 PZEV CYLINDER HEAD
1 - Air Injection Ports_1
2 - Exhaust Parts_2
JR
ENGINE 2.4L DOHC
9 - 97
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE
PRESSURE
BUILT
UP,
BY
CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester’s pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(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).
(4) Remove throttle body air inlet hose and air
cleaner housing assembly.
(5) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(6) Disconnect heater hose from thermostat hous-
ing.
(7) Remove heater tube support bracket from cyl-
inder head.
(8) Disconnect camshaft position sensor electrical
connector.
(9) Disconnect EGR solenoid electrical connector.
(10) Disconnect connector tube from the one way
check valve (Fig. 11).
(11) Raise vehicle on hoist.
(12) Disconnect exhaust pipe from exhaust mani-
fold.
(13) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(14) Remove crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(15) Remove upper and lower timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(16) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(17) Remove camshaft sprockets (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - REMOVAL).
(18) Remove timing belt idler pulley and rear tim-
ing belt cover.
(19) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(20) Remove camshafts and rocker arms (Refer to
9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) -
REMOVAL).
(21)
Remove cylinder head bolts and remove cyl-
inder head from engine block.
(22) Inspect and clean cylinder head (Refer to 9 -
ENGINE - STANDARD PROCEDURE).
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
Fig. 11 QUICK CONNECTOR OPERATION
9 - 98
ENGINE 2.4L DOHC
JR
CYLINDER HEAD (Continued)
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