Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 508
NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
(5) Install new front crankshaft seal using Special
Tool 6780 (Fig. 101).
(6) Install crankshaft sprocket using Special Tool
6792 (Fig. 102).
(7) Install oil pump pick-up tube.
(8) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(9) Install Timing Belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION).
(10) Install
crankshaft
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(11) Replace oil filter.
(12) Lower vehicle.
(13) Fill engine crankcase with proper oil to cor-
rect level.
(14) Connect negative battery cable.
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.
Fig. 101 Front Crankshaft Seal—Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 102 Crankshaft Sprocket—Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
JR
ENGINE 2.4L DOHC
9 - 135
OIL PUMP (Continued)
(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 throttle and speed control cables from
throttle lever and bracket.
(6) Remove EGR tube.
(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 gasket for surface damage or
excessive swelling. Replace gaskets as 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 (Refer to 25 - EMISSIONS
CONTROL/EXHAUST
GAS
RECIRCULATION/
TUBE - INSTALLATION).
(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.
Fig. 103 Fuel Rail Support Bracket
9 - 136
ENGINE 2.4L DOHC
JR
INTAKE MANIFOLD (Continued)
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.
(5) Disconnect connector tube from check valve (if
equiped). Squeeze connector as shown and pull (Fig.
105) (Fig. 106).
(6) Remove exhaust manifold heat shield (Fig.
107).
(7) Disconnect oxygen sensor electrical connector.
(8) Remove exhaust manifold retaining fasteners
and remove exhaust manifold.
(9) Remove and discard manifold gasket.
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
Fig. 104 Intake Manifold Tightening Sequence
Fig. 105 CONNECTOR TUBE QUICK CONNECT
Fig. 106 PZEV Manifold and Check Valve
1 - Check Valve
2 - Exhaust Manifold
3 - Heat Sheild Mounting Location
Fig. 107 Exhaust Manifold Heat Shield Bolts-Typical
1 - BOLTS
JR
ENGINE 2.4L DOHC
9 - 137
INTAKE MANIFOLD (Continued)
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
There are two different exhaust manifolds that are
used on the 2.4L engine. The PZEV manifold has a
check valve attached to it. Each manifold has a dif-
ferent torque sequence that must be followed.
(1) Install new exhaust manifold gasket. DO NOT
APPLY SEALER.
(2) Position exhaust manifold in place. Tighten fas-
teners in sequence shown in (Fig. 108) for non-PZEV
engines to 23 N·m (200 in. lbs.). For PZEV engines
tighten bolts (Fig. 109) to 23 N·m (200 in. lbs.).
Repeat this procedure until all fasteners are at spec-
ified torque.
(3) Install exhaust manifold heat shield.
(4) Install check valve tighten bolts to 12 N·m (105
in. lbs.) (if equiped).
(5) Connect connector tube to check valve by push-
ing fitting over check valve.
(6) Connect oxygen sensor electrical connector.
(7) Install
rear
engine
mount
and
transaxle
bracket.
(8) Install
exhaust
system
(Refer
to
11
-
EXHAUST SYSTEM - INSTALLATION). Tighten fas-
teners to 28 N·m (250 in. lbs.).
(9) Lower vehicle.
(10) Connect negative battery cable.
TIMING BELT COVER(S)
REMOVAL
FRONT COVER - UPPER
(1) Remove upper timing belt cover fasteners (Fig.
110) and remove cover.
FRONT COVER - LOWER
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove right front wheel and belt splash
shield.
(4) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(5) Remove crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(6) Remove AC/Generator belt tensioner.
(7) Lower vehicle.
(8) Disconnect generator connectors.
(9)
Remove generator and bracket.
(10) Raise vehicle on hoist.
(11) Remove
fasteners
attaching
lower
timing
cover (Fig. 110).
(12) Remove lower timing cover.
REAR COVER
(1) Remove upper and lower front timing belt cov-
ers.
Fig. 108 Exhaust Manifold Tightening Sequence-
Typical
Fig. 109 PZEV Exhaust Manifold Tightening
Sequence
9 - 138
ENGINE 2.4L DOHC
JR
EXHAUST MANIFOLD (Continued)
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