Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 495
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-
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. 3)
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. 3)
• Drill motor with 3M Roloc™ Bristle Disc (white
or yellow) (Fig. 3)
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.
MEASURING BEARING CLEARANCE USING
PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1)
Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
Fig. 3 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOC™ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
JR
ENGINE 2.4L DOHC
9 - 83
ENGINE 2.4L DOHC (Continued)
holes (Fig. 4). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap/bed plate bolts of the
bearing being checked to the proper specifications.
(3)
Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare clearance measurements to specs found in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS). Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install
the
proper
crankshaft
bearings
to
achieve the specified bearing clearances.
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
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) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
(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) Remove upper radiator crossmember.
(7) Disconnect upper and lower radiator hoses at
radiator.
(8) 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.
(9) Disconnect A/C lines at condenser. Remove
cooling module assembly (radiator, fan module, and
condenser).
(10) Disconnect
transmission
electrical
harness
connectors (C104 & C105) (Refer to 8 - ELECTRI-
CAL/CONNECTOR/GROUND
LOCATIONS
-
DESCRIPTION).
Fig. 4 Plastigage Placed in Lower Shell—Typical
1 - PLASTIGAGE
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
9 - 84
ENGINE 2.4L DOHC
JR
ENGINE 2.4L DOHC (Continued)
(11) Disconnect transmission shift cable.
(12) Disconnect engine electrical harness from
PCM and bulkhead connectors.
(13) Raise vehicle on hoist.
(14) Remove both front wheels.
(15) Remove left and right splash shields.
(16) Remove both axle shafts (Refer to 3 - DIF-
FERENTIAL
&
DRIVELINE/HALF
SHAFT
-
REMOVAL).
(17) Drain engine oil.
(18) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(19) Remove power steering pump from bracket.
Do not disconnect power steering lines from pump.
Reposition pump and support with suitable retaining
strap.
(20) Disconnect heater return hose from pipe con-
nection at right front frame rail area.
(21) Disconnect A/C compressor electrical connec-
tors.
(22) Disconnect exhaust pipe from manifold.
(23) Remove through bolts from front and rear
engine mounts.
(24) Remove rear mount bracket from transmis-
sion.
(25) Remove structural collar and torque reaction
bracket (Refer to 9 - ENGINE/ENGINE BLOCK/
STRUCTURAL COVER - REMOVAL).
(26) Mark flex plate to torque converter position.
Remove torque converter bolts.
(27) Lower vehicle.
(28) Disconnect positive cable from battery and
PDC.
(29) Disconnect ground cable from left side trans-
axle mount bracket.
(30) Disconnect throttle and speed control cables.
(31) Disconnect coolant recovery container over-
flow hose.
(32) Disconnect heater hose at thermostat housing.
(33) Disconnect all ground straps attaching to
engine.
(34) Disconnect brake booster and vapor purge
vacuum hoses.
(35) Disconnect fuel line from fuel rail.
(36) Disconnect generator connectors.
(37) Remove
intake
manifold
(Refer
to
9
-
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL).
(38) Remove generator.
(39) Remove AIR pump (if equiped) (Refer to 25 -
EMISSIONS CONTROL/AIR INJECTION/PUMP -
REMOVAL).
(40) Remove A/C suction line at compressor. Cap
suction port and line.
(41) Remove A/C compressor.
(42) Raise vehicle enough to allow engine dolly
6135 and cradle 6710 with posts 6848 to be installed
under vehicle (Fig. 6).
(43) Loosen cradle engine mounts to allow move-
ment for positioning onto engine locating holes on the
engine bedplate, compressor and support bracket.
Install adapters 6909 to the two post at rear of
engine. Lower vehicle and position cradle mounts
until the engine is resting on posts. Tighten post
mounts to cradle frame. This will keep mounts from
moving when removing or installing engine/transmis-
sion assembly. Secure engine/transmission to dolly/
cradle with safety straps.
(44) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle.
(45) Remove right and left side vertical engine
mount bolts.
(46) 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.
(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) Install A/C compressor.
(5) Connect A/C suction line to compressor.
(6) Install AIR pump (if equiped) (Refer to 25 -
EMISSIONS CONTROL/AIR INJECTION/PUMP -
INSTALLATION).
(7) Install generator.
(8) Install intake manifold. Torque fasteners to 12
N·m (105 in. lbs.) (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - INSTALLATION).
(9) Connect generator connectors.
(10) Connect fuel line to fuel rail.
(11) Connect brake booster and vapor purge hoses.
(12) Connect all ground straps to engine.
(13) Connect heater hose to thermostat housing.
(14) Connect coolant recovery container overflow
hose.
(15) Connect throttle and speed control cables.
(16) Connect ground cable to left side transaxle
mount bracket.
JR
ENGINE 2.4L DOHC
9 - 85
ENGINE 2.4L DOHC (Continued)
Fig. 6 Positioning Engine Cradle Support Post Mounts
1 - SPECIAL TOOLS POST 6848
2 - SPECIAL TOOLS POST 6848 WITH ADAPTERS 6909
3 - SPECIAL TOOL 6135 DOLLY
4 - SPECIAL TOOL 6710 CRADLE
9 - 86
ENGINE 2.4L DOHC
JR
ENGINE 2.4L DOHC (Continued)
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