Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 514
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
STANDARD PROCEDURE
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug
and camshaft bearing cap attaching threads) can be
repaired. Essentially, this repair consists of drilling
out worn or damaged threads, tapping the hole with
a special Heli-Coil Tap, (or equivalent) and installing
an insert into the tapped hole. This brings the hole
back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect
air
cleaner,
induction
system
and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when
applying
form-in-place
gaskets
to
assure
obtaining the desired results. Do not use form-in-
place gasket material unless specified. Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopar
t
Engine RTV GEN II, Mopar
t ATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPAR
t ENGINE RTV GEN II is used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains
adhesion
and
sealing
properties
when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPAR
t ATF RTV is a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPAR
t GASKET MAKER is an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPAR
t BED PLATE SEALANT is a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed
plate and cylinder block without disturbing the bear-
JR
ENGINE 2.7L DOHC
9 - 159
ENGINE 2.7L DOHC (Continued)
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPAR
t GASKET SEALANT is a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer
steel
(MLS)
cylinder
head
gaskets.
This
material also will prevent corrosion. Mopar
t Gasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
Mopar
t Gasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
Mopar
t Engine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
Mopar
t Gasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
ENGINE GASKET SURFACE PREPARATION
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.
Never use the following to clean gasket surfaces:
• Metal scraper
• Abrasive pad or paper to clean cylinder block
and head
• High speed power tool with an abrasive pad or a
wire brush (Fig. 4)
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
• Solvent or a commercially available gasket
remover
• Plastic or wood scraper (Fig. 4)
• Drill motor with 3M Roloc™ Bristle Disc (white
or yellow) (Fig. 4)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
ENGINE CORE AND OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 5).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopar
t
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
Fig. 4 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOC™ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
9 - 160
ENGINE 2.7L DOHC
JR
ENGINE 2.7L DOHC (Continued)
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
REMOVAL - ENGINE ASSEMBLY
(1) Release fuel pressure (Refer to 14 - FUEL SYS-
TEM/FUEL
DELIVERY
-
STANDARD
PROCE-
DURE).
(2) Disconnect negative battery cable.
(3) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(4) Discharge A/C system using a suitable refriger-
ant recovery machine.
(5) Remove throttle body air inlet hose and air
cleaner housing assembly.
(6) Raise vehicle on hoist.
(7) Remove both front wheels.
(8) Remove left and right splash shields.
(9) Remove fasteners attaching lower front fascia
to crossmember.
(10) Remove fasteners attaching lower air shield to
crossmember.
(11) Remove front bumper fascia.
(12) Lower vehicle.
(13) Remove upper radiator crossmember.
(14) Disconnect upper and lower radiator hoses at
radiator.
(15) Automatic Transmission Equipped Vehi-
cles:
• Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug lines
and fittings to prevent debris from entering transaxle
or cooler circuit. A service splice kit will be installed
upon reassembly.
• Disconnect transmission electrical harness con-
nectors (C104 & C105) (Refer to 8 - ELECTRICAL/
CONNECTOR/GROUND
LOCATIONS
-
DESCRIPTION).
• Disconnect transmission shift cable.
(16) Manual Transmission Equipped Vehicles:
• Disconnect transmission shift cables and remove
from retaining bracket.
• Disconnect back up lamp switch connector.
(17) Disconnect A/C lines at condenser. Remove
cooling module (fan, radiator, A/C condenser).
(18) Disconnect engine electrical harness from
PCM and bulkhead connectors.
(19) Remove fasteners attaching ABS brake mod-
ule to lower radiator crossmember. Support module
with a suitable retaining strap.
(20) Disconnect brake line from retaining clips
that attach to lower radiator crossmember.
(21) Raise vehicle.
(22) Remove both axle shafts (Refer to 3 - DIF-
FERENTIAL
&
DRIVELINE/HALF
SHAFT
-
REMOVAL).
(23) Remove front engine mount through bolt.
Remove front engine mount from lower radiator
crossmember.
(24) Remove lower radiator crossmember.
(25) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(26) Remove power steering pump and bracket as
an assembly. Do not disconnect power steering lines
from pump. Reposition pump and support with suit-
able retaining strap.
(27) Disconnect heater return hose from pipe con-
nection at right front frame rail area.
(28) Disconnect A/C compressor electrical connec-
tor.
(29) Remove A/C compressor mounting bolts. Repo-
sition A/C compressor and support with suitable
retaining strap. Generator can be removed with
engine assembly.
(30) Remove
structural
collar
(Refer
to
9
-
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL).
(31) Remove the exhaust cross-under pipe (Refer
to 11 - EXHAUST SYSTEM/CROSS-OVER PIPE -
REMOVAL).
(32) Remove rear engine mount and transaxle
bracket.
(33) Drain engine oil.
(34) Automatic Transmission Equipped Vehi-
cles:
• Remove transaxle torque converter housing
cover.
Fig. 5 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
JR
ENGINE 2.7L DOHC
9 - 161
ENGINE 2.7L DOHC (Continued)
• Mark flex plate to torque converter position.
Remove torque converter bolts.
(35) Manual Transmission Equipped Vehicles:
• Using Special Tool 6638, disconnect clutch
hydraulic circuit quick connect fitting.
• Remove clutch/drive plate inspection cover.
• Mark flex plate to modular clutch position.
Remove modular clutch assembly-to-drive plate bolts.
(36) Lower vehicle.
(37) Disconnect positive cable from battery and
PDC.
(38) Disconnect ground cable from left side trans-
axle mount bracket.
(39) Disconnect throttle and speed control cables.
(40) Disconnect coolant pressure bottle coolant
hose from engine coolant outlet connector.
(41) Disconnect heater hose from engine coolant
outlet connector.
(42) Disconnect ground strap at right shock tower.
(43) Disconnect fuel line.
(44) Disconnect brake booster and vapor purge
vacuum hoses.
(45) Disconnect all ground straps attaching to
engine.
(46) Position vehicle height to allow engine dolly
6135 and cradle 6710 with posts 6848 to be installed
under vehicle.
(47) Loosen cradle engine mounts to allow move-
ment for positioning onto engine locating holes on the
engine block, compressor mount bracket and oil pan
rail. Lower vehicle and position cradle until the
engine is resting on posts (Fig. 6). Tighten post
mounts to cradle frame to prevent movement when
removing or installing engine/transaxle assembly.
Secure engine/transaxle assembly to dolly/cradle with
safety straps.
(48) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle.
(49) Remove right and left side engine mount
bolts.
(50) Slowly raise vehicle in short length spans.
Inspect at each interval for potential engine or trans-
axle contact to vehicle components. Move the cradle/
dolly fixture as necessary to allow for removal
clearance.
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine/transaxle assembly under vehi-
cle and slowly lower vehicle in short length spans.
Inspect at each interval for potential engine or trans-
axle contact to vehicle components. Move the cradle/
dolly fixture as necessary to allow for installation
clearance (Fig. 6).
(2) Continue lowering vehicle until right side
engine mount and left side transaxle mount align to
their mounting locations. Install mounting bolts and
torque to 61 N·m (45 ft. lbs.).
(3) Remove safety straps from engine/transaxle
assembly. Slowly raise vehicle enough to remove the
engine dolly and cradle.
(4) Reattach all ground straps to engine.
(5) Connect brake booster and vapor purge vac-
uum hoses.
(6) Connect fuel line.
(7) Connect ground strap to right shock tower.
(8) Connect heater hose to coolant outlet connector.
(9) Connect coolant pressure bottle coolant hose to
coolant outlet connector.
(10) Connect throttle and speed control cables.
(11) Connect ground cable to left side transaxle
mount bracket.
(12) Connect positive cable to battery and PDC.
(13) Raise vehicle.
(14) Automatic Transmission Equipped Vehi-
cles:
• Install torque converter bolts.
• Install torque converter housing cover.
(15) Manual Transmission Equipped Vehicles:
• Install modular clutch assembly-to-drive plate
bolts.
• Install clutch/drive plate inspection cover.
• Connect clutch hydraulic circuit quick connect
fitting.
(16) Install rear engine mount and transaxle
bracket.
Fig. 6 ENGINE REMOVAL CRADLE
1 - SAFETY STRAPS
2 - SPECIAL TOOL 6135
3 - SPECIAL TOOL 6710
9 - 162
ENGINE 2.7L DOHC
JR
ENGINE 2.7L DOHC (Continued)
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