Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 496
(17) Connect positive cable to battery and PDC.
(18) Raise vehicle on hoist.
(19) Install torque converter bolts.
(20) Install structural collar and torque reaction
bracket (Refer to 9 - ENGINE/ENGINE BLOCK/
STRUCTURAL COVER - INSTALLATION).
(21) Install rear mount bracket to transmission.
(22) Install front and rear engine mount through
bolts. Torque fasteners to 61 N·m (45 ft. lbs.).
(23) Connect exhaust pipe to exhaust manifold.
Torque fasteners to 28 N·m (250 in. lbs.).
(24) Connect A/C compressor electrical connectors.
(25) Connect heater return hose to pipe connection
at right front frame rail area.
(26) Install power steering pump to bracket.
(27) Install accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(28) Install both axle shafts (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION).
(29) Install new oil filter.
(30) Install left and right splash shields.
(31) Install both front wheels.
(32) Lower vehicle.
(33) Connect engine electrical harness to PCM and
bulkhead connectors.
(34) Connect transmission shift cable.
(35) Connect
transmission
electrical
connectors
(C104 & C105) (Refer to 8 - ELECTRICAL/CONNEC-
TOR/GROUND LOCATIONS - DESCRIPTION).
(36) Install cooling module assembly (radiator, fan
module, and condenser). Connect A/C lines to con-
denser.
(37) Connect transmission oil cooler lines using
service splice kit. Refer to instructions provided with
kit.
(38) Connect upper and lower radiator hoses.
(39) Install upper radiator crossmember.
(40) Install throttle body air inlet hose and air
cleaner housing assembly.
(41) Fill engine crankcase with proper oil to cor-
rect level.
(42) Evacuate and recharge A/C system (Refer to
24 - HEATING & AIR CONDITIONING - STAN-
DARD PROCEDURE).
(43) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(44) Connect negative battery cable.
(45) Start engine and run until normal operating
temperature is reached.
SPECIFICATIONS
2.4L ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Type
In-Line OHV, DOHC
Number of
Cylinders
4
Firing Order
1-3-4-2
Compression
Ratio
9.5:1
Max. Variation
Between
Cylinders
25%
Displacement
2.4 Liters
148 cu. in.
Bore
87.5 mm
3.445 in.
Stroke
101.0 mm
3.976 in.
Compression
Pressure
1172-1551 kPa
170-225 psi
CYLINDER BLOCK
DESCRIPTION
SPECIFICATION
Metric
Standard
Cylinder Bore
Diameter
87.4924-
87.5076 mm
3.4446-3.4452
in.
Out-of-Round
(Max.)
0.051 mm
0.002 in.
Taper (Max.)
0.051 mm
0.002 in.
JR
ENGINE 2.4L DOHC
9 - 87
ENGINE 2.4L DOHC (Continued)
PISTONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Piston Diameter
87.456-87.474
mm
3.4431-3.4439
in.
Clearance @
24.6 mm (0.551
in.) from bottom
of skirt
0.018-0.0516
mm
0.0007-0.0020
in.
Weight
345-355 grams
12.17-12.52 oz.
Land Clearance
(Diametrical)
0.563-0.621
mm
0.022-0.024 in.
Piston Length
66.25 mm
2.608 in.
Piston Ring
Groove Depth
No. 1
3.946-4.045
mm
0.155-0.159 in.
Piston Ring
Groove Depth
No. 2
4.555-4.680
mm
0.179-0.184 in.
Piston Ring
Groove Depth
No. 3
4.108-4.220
mm
0.162-0.166 in.
PISTON PINS
DESCRIPTION
SPECIFICATION
Metric
Standard
Clearance in
Piston
Non-Turbo
0.005-0.018
mm
0.0002-0.0008
in.
Turbo
0.004-0.014
mm
0.0001-0.0005
in.
Clearance in
Connecting Rod
Non-Turbo
Interference
Turbo
0.007-0.018
mm
0.0002-0.0007
in.
Diameter
Non-Turbo
21.99822.003
mm
0.8660-0.8662
in.
Turbo
21.997-22.000
mm
0.8660-0.8661
in.
End Play
Non-Turbo
None
DESCRIPTION
SPECIFICATION
Metric
Standard
Turbo
0.34-1.44 mm
0.0133-0.0566
in.
Length
Non-Turbo
72.75-73.25
mm
2.864-2.883 in.
Turbo
65.41-65.85
mm
2.575-2.592 in.
PISTON RINGS
DESCRIPTION
SPECIFICATION
Metric
Standard
Ring Gap-Top
Compression
Ring
0.25-0.51 mm
0.0098-0.020 in.
Wear Limit
0.8 mm
0.031 in.
Ring Gap-2nd
Compression
Ring
0.23-0.48 mm
0.009-0.018 in.
Wear Limit
0.8 mm
0.031 in.
Ring Gap-Oil
Control Steel
Rails
0.25-0.64 mm
0.009-0.025 in.
Wear Limit
1.0 mm
0.039 in.
Ring Side
Clearance-
Compression
Rings
0.030-0.080
mm
0.0011-0.0031
in.
Wear Limit
0.10 mm
0.004 in.
Ring Side
Clearance-Oil
Ring Pack
0.012-0.178
mm
0.0004-0.0070
in.
Ring Width-
Compression
Rings
1.47-1.50 mm
0.057-0.059 in.
Ring Width-Oil
Ring Pack
2.72–2.88 mm
0.107–0.1133
in.
9 - 88
ENGINE 2.4L DOHC
JR
ENGINE 2.4L DOHC (Continued)
CONNECTING ROD
DESCRIPTION
SPECIFICATION
Metric
Standard
Bearing
Clearance
0.025–0.071
mm
0.0009–0.0027
in.
Wear Limit
0.075 mm
0.003 in.
Bore Diameter-
Piston Pin
20.96–20.98
mm
0.8664-0.8667
in.
Bore Diameter-
Crankshaft End
52.993-53.007
mm
2.0863-2.0868
in.
Side Clearance
0.13–0.38 mm
0.005–0.015 in.
Wear Limit
0.40 mm
0.016 in.
Weight-Total
(Less Bearing)
565.8 grams
19.96 oz.
CRANKSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Connecting Rod
Journal
Diameter
49.984 - 50.000
mm
1.968 - 1.9685
in.
Main Bearing
Journal
Diameter
59.992 - 60.008
mm
2.362 - 2.3625
in.
Journal
Out-of-Round
(Max.)
0.0035 mm
0.0003 in.
Journal Taper
(Max.)
0.007 mm
0.0001 in.
End Play
0.09 - 0.24 mm
0.0035 - 0.0094
in.
Wear Limit
0.38 mm
0.015 in.
Main Bearing
Diametrical
Clearance
0.018 - 0.062
mm
0.0007 - 0.0024
in.
HYDRAULIC LASH ADJUSTER
DESCRIPTION
SPECIFICATION
Metric
Standard
Body Diameter
15.901 - 15.913
mm
0.626 - 0.6264
in.
DESCRIPTION
SPECIFICATION
Metric
Standard
Plunger Travel
Minimum (Dry)
3.0 mm
0.118 in.
CYLINDER HEAD CAMSHAFT BEARING BORE
DIAMETER
DSECRIPTION
SPECIFICATION
Metric
Standard
Journals No.1 -
6
26.020 - 26.041
mm
1.024 - 1.025 in.
CAMSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Journal
Diameter No.
1–6
25.976 - 25.995
mm
1.022 - 1.023 in.
Bearing
Clearance -
Diametrical
0.025 - 0.065
mm
0.0009 - 0.0025
in.
End Play
0.05 - 0.17 mm
0.0019 - 0.0066
in.
Lift (Zero Lash)
Intake
8.25 mm
(0.324 in.)
Exhaust
6.60 mm
(0.259 mm)
Intake Valve
Timing*
Closes (ABDC)
44.3°
Opens (ATDC)
6.2°
Duration
218°
Exhaust Valve
Timing*
Closes (ATDC)
0.8°
Opens (BBDC)
39.9°
Duration
220.7°
Valve Overlap
5.4°
*
All reading in crankshaft degrees at 0.5 mm (0.019
in.) valve lift.
JR
ENGINE 2.4L DOHC
9 - 89
ENGINE 2.4L DOHC (Continued)
CYLINDER HEAD
DESCRIPTION
SPECIFICATION
Metric
Standard
Material
Cast Aluminum
Gasket
Thickness
(Compressed)
0.71 mm
0.028 in.
VALVE SEAT
DESCRIPTION
SPECIFICATION
Metric
Standard
Angle
44.5 - 45°
Seat Diameter -
Intake
34.37 - 34.63
mm
1.353 - 1.363 in.
Seat Diameter -
Exhaust
27.06 - 27.32
mm
1.065 - 1.075 in.
Runout (Max.)
0.05 mm
0.002 in.
Valve Seat
Width - Intake
and Exhaust
0.9 - 1.3 mm
0.035 - 0.051 in.
Service Limit -
Intake
2.0 mm
0.079 in.
Service Limit -
Exhaust
2.5 mm
0.098 in.
VALVE GUIDE
DESCRIPTION
SPECIFICATION
Metric
Standard
Diameter I.D.
5.975 - 6.000
mm
0.235 - 0.236 in.
Guide Bore
Diameter
11.0 - 11.02
mm
0.4330 - 0.4338
in.
Guide Height
(spring seat to
guide tip)
13.25 - 13.75
mm
0.521 - 0.541 in.
VALVES
DESCRIPTION
SPECIFICATION
Metric
Standard
Face Angle -
Intake and
Exhaust
44.5 - 45°
Head Diameter
- Intake
34.67 - 34.93
mm
1.364 - 1.375
in.)
Head Diameter
- Exhaust
28.32 - 28.52
mm
1.114 - 1.122 in.
Valve Length
(Overall)
Intake
112.76 - 113.32
mm
4.439 - 4.461 in.
Exhaust
110.89 - 111.69
mm
4.365 - 4.397 in.
Valve Stem
Diameter
Intake
5.934 - 5.952
mm
0.2337 - 0.2344
in.
Exhaust
5.906 - 5.924
mm
0.2326 - 0.2333
in.
VALVE MARGIN
DESCRIPTION
SPECIFICATION
Metric
Standard
Intake
1.2 - 1.7 mm
0.047 - 0.066 in.
Service Limit
0.95 mm
(.0037 in.)
Exhaust
0.985 - 1.315
mm
0.038 - 0.051 in.
Service Limit
1.05 mm
.039 in.
VALVE STEM TIP
DESCRIPTION
SPECIFICATION
Metric
Standard
Intake
48.04 mm
1.891 in.
Exhaust
47.99 mm
1.889 in.
9 - 90
ENGINE 2.4L DOHC
JR
ENGINE 2.4L DOHC (Continued)
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