Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 518
INSTALLATION
(1) Install air cleaner housing straight down on
locating pins.
(2) Install nut on bracket that holds air cleaner
housing and tighten.
(3) Install throttle body air inlet hose to throttle
body. Tighten hose clamp (Fig. 14).
(4) Connect fresh air makeup hose (Fig. 13).
(5) Connect inlet air temperature sensor electrical
connector (Fig. 12).
(6) Connect negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cylinder heads are made of an aluminum alloy
(Fig. 15). The cylinder head features four valves per
cylinder with pressed in powdered metal valve
guides. The cylinder heads provide enclosures for the
timing chain drive, necessitating a unique right and
left cylinder head.
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.
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.
Fig. 14 HOSE CLAMP
JR
ENGINE 2.7L DOHC
9 - 175
AIR CLEANER HOUSING (Continued)
STANDARD PROCEDURE - Cylinder Head Oil
Gallery Cup Plug Service
NOTE: DETERMINE WHICH CUP PLUG IS LEAKING
BEFORE PERFORMING THIS PROCEDURE. IF NEC-
ESSARY, PERFORM AN ENGINE OIL LEAK DYE
TEST.
Each cylinder head on a 2.7L engine has 6 external
oil gallery cup plugs. It is not necessary to remove
the original cup plug to install a new cup plug. The
cup plug bore is deep enough to allow for two plugs.
If it becomes necessary to service an oil gallery cup
plug, perform the Repair Procedure.
NOTE: INSPECT THE CUP PLUG BORE IN QUES-
TION FOR THE PRESENCE OF TWO CUP PLUGS. IF
THE CUP PLUG FLANGE IS JUST INSIDE (1–2 MM)
THE CHAMFERED EDGE OF THE BORE TWO CUP
PLUGS ARE ALREADY IN PLACE AND THE CYLIN-
DER HEAD CANNOT BE REPAIRED.
Repair Procedure
(1) Remove component(s) necessary to gain access
to the oil gallery cup plug requiring service.
NOTE: SOME OF THE OIL GALLERY CUP PLUGS
ARE SERVICEABLE WITH THE HEAD INSTALLED
ON THE ENGINE AND THE ENGINE IN THE VEHI-
CLE, WHILE OTHERS REQUIRE REMOVING THE
AFFECTED CYLINDER HEAD FROM THE ENGINE.
IN EITHER CASE ONLY REPLACE THE CUP PLUG
REQUIRING SERVICE.
(2) Clean the cup plug bore with brake cleaner and
compressed air. It is not necessary to remove the
existing cup plug.
(3) Lightly coat the new cup plug with sealer; p/n
04318083.
(4) Using an appropriate installation tool drive the
new cup plug into the bore until the flanged edge of
the plug is just inside (1-2 mm) the chamfered edge
of the bore (Fig. 16).
Fig. 15 CYLINDER HEAD, VALVES, & SPRINGS
1 - VALVE KEEPER
7 - VALVE-EXHAUST
2 - SPRING RETAINER
8 - VALVE-INTAKE
3 - VALVE KEEPER
9 - CYLINDER HEAD
4 - VALVE SPRING-EXHAUST
10 - VALVE STEM SEAL
5 - SPRING RETAINER
11 - VALVE SPRING-INTAKE
6 - VALVE STEM SEAL
9 - 176
ENGINE 2.7L DOHC
JR
CYLINDER HEAD (Continued)
(5) Allow the sealant to cure for at least 20 min-
utes.
(6) Assemble any components removed in step # 1
as necessary.
REMOVAL
(1) Perform fuel pressure release procedure before
attempting any repairs. (Refer to 14 - FUEL SYS-
TEM/FUEL
DELIVERY
-
STANDARD
PROCE-
DURE)
(2) Disconnect negative cable from remote jumper
terminal.
(3) Raise vehicle on hoist.
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(5) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(6) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(7) Remove exhaust cross-under pipe (Refer to 11 -
EXHAUST
SYSTEM/CROSS-OVER
PIPE
-
REMOVAL).
(8) Remove the appropriate catalytic converter
(Refer to 11 - EXHAUST SYSTEM/CATALYTIC
CONVERTER - REMOVAL).
(9) Remove oil pressure sensor heat shield. Discon-
nect oil pressure sensor connector.
(10) Lower vehicle.
(11) Remove upper and lower intake manifolds
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - REMOVAL).
(12) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL).
(13) Disconnect
camshaft
position
sensor
and
crankshaft position sensor connectors.
(14) Reposition engine wiring harness to left side
of vehicle.
(15) Remove coolant outlet connector (Fig. 17)
(Refer to 7 - COOLING/ENGINE/COOLANT OUT-
LET HOUSING - REMOVAL).
(16) Remove timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING CHAIN COVER -
REMOVAL).
(17) Rotate crankshaft until crankshaft sprocket
timing mark aligns with timing mark on oil pump
housing.
(18) Remove primary timing chain (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
CHAIN
AND
SPROCKETS - REMOVAL).
(19) Remove upper primary timing chain guides.
(20) Remove camshaft bearing caps gradually in
REVERSE sequence of installation (10–1) (Fig. 18).
(21) Remove camshafts and valvetrain components
from cylinder head (Fig. 19). Note component loca-
tions for re-installation in original locations.
(22) For left cylinder head removal:
• Remove fastener securing engine oil dipstick
tube to cylinder head. Remove engine oil dipstick
tube.
• Remove generator.
Fig. 16 Oil Gallery Cup Plug
1 – CUP PLUG BORE CHAMFER
2 – ORIGINAL CUP PLUG
3 – NEW CUP PLUG
4 – 1–2 mm
Fig. 17 Coolant Outlet Connector- 2.7L
1 - BOLT (2)
2 - BOLT (2)
3 - COOLANT OUTLET CONNECTOR
JR
ENGINE 2.7L DOHC
9 - 177
CYLINDER HEAD (Continued)
(23) For right cylinder head removal:
• Remove cylinder head ground strap.
• Disconnect EGR valve electrical connector (if
equipped).
CAUTION: Ensure cylinder head bolts 11–9 (Fig. 20)
are removed before attempting the removal of cylin-
der head, as damage to cylinder head and/or block
may occur.
(24) Remove
cylinder
head
bolts
in
reverse
sequence of installation (Fig. 20) starting with bolts
11–9, then bolts 8–1.
Fig. 19 Camshaft & Valvetrain Components
1 – CAMSHAFT BEARING CAP - INTAKE
7 – CAMSHAFT (SECONDARY) CHAIN TENSIONER
2 – CAMSHAFT BEARING CAP - EXHAUST
8 – CYLINDER BLOCK
3 – CAMSHAFT - EXHAUST
9 – CYLINDER HEAD
4 – ROCKER ARM
10 – CAMSHAFT - INTAKE
5 – HYDRAULIC LIFTER
11 – CAMSHAFT (SECONDARY) TIMING CHAIN
6 – CYLINDER HEAD
Fig. 18 Camshaft Bearing Caps
Fig. 20 CYLINDER HEAD BOLTS
9 - 178
ENGINE 2.7L DOHC
JR
CYLINDER HEAD (Continued)
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