Chrysler Stratus Convertible. Manual — part 386

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.

REPAIR OF DAMAGED OR WORN THREADS

Damaged or worn threads (including aluminum

head spark plug threads) can be repaired. Essen-
tially, 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 centerline.

Heli-Coil tools and inserts are readily available

from automotive parts jobbers.

CYLINDER BORE—HONING

(1) Used carefully, the cylinder bore resizing hone,

recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.

(2) Deglazing of the cylinder walls may be done

using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20–60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Inspect cyl-

inder walls after each 20 strokes, using a light
honing oil. Do not use engine or transmission oil,
mineral spirits or kerosene.

(3) Honing should be done by moving the hone up

and down fast enough to get a cross-hatch pattern.
When hone marks intersect at 50-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 13).

(4) A

controlled

hone

motor

speed

between

200–300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50–60
degree angle. Faster up and down strokes increase
the cross-hatch angle.

(5) After honing, it is necessary that the block be

cleaned again to remove all traces of abrasive.

CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.

CYLINDER BORE AND PISTON—SIZING

The cylinder walls should be checked for out-of-

round and taper with Tool C-119 (Fig. 14). Refer to
Engine Specifications for cylinder bore out-of-round
and cylinder bore taper specifications. If the cylinder
walls are badly scuffed or scored, the cylinder block
should be rebored and honed, and new pistons and
rings fitted. Whatever type of boring equipment is
used, boring and honing operation should be closely

Fig. 12 Proper Tool Usage For Surface Preparation

Fig. 13 Cylinder Bore Cross-Hatch Pattern

1 – CROSS-HATCH PATTERN

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2.0L SOHC ENGINE

9 - 17

SERVICE PROCEDURES (Continued)

coordinated with the fitting of pistons and rings in
order that specified clearances may be maintained.
Refer to Honing Cylinder Bores outlined in the
Standard Service Procedures for specification
and procedures.

Measure the cylinder bore at three levels in direc-

tions A and B (Fig. 14). Top measurement should be
10 mm (3/8 inch) down and bottom measurement
should be 10 mm (3/8 inch.) up from bottom of bore.
Refer to Engine Specifications.

SIZING PISTONS

Piston and cylinder wall must be clean and dry.

Piston diameter should be measured 90 degrees to
piston pin about 17.5 mm (11/16 inch) from the bot-
tom of the skirt as shown in (Fig. 15). Cylinder bores
should be measured halfway down the cylinder bore
and transverse to the engine crankshaft center line
shown in (Fig. 14). Refer to Engine Specifications.
Correct piston to bore clearance must be established
in order to assure quiet and economical operation.

DaimlerChrysler engines use pistons designed spe-

cifically for each engine model. Clearance and sizing
locations vary with respect to engine model.

NOTE: Pistons and cylinder bores should be mea-
sured at normal room temperature, 21°C (70°F).

PISTON RING—FITTING

(1) Wipe cylinder bore clean. Insert ring and push

down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioned below normal ring travel in the cylinder

bore. Check gap with feeler gauge (Fig. 16). Refer to
Engine Specifications in this section for piston ring
specifications.

(2) Check piston ring to groove side clearance (Fig.

17). Refer to Engine Specifications in this section for
piston ring specifications.

CONNECTING ROD AND BEARING—FITTING

CONNECTING ROD BEARING CLEARANCE

Engine connecting rod bearing clearances can be

determined by use of Plastigage or equivalent. The
following is the recommended procedure for the use
of Plastigage:

(1) Rotate the crankshaft until the connecting rod

to be checked is at the bottom of its stroke.

(2) Remove oil film from surface to be checked.

Plastigage is soluble in oil.

(3) Place a piece of Plastigage across the entire

width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from

Fig. 14 Checking Cylinder Bore Size

Fig. 15 Piston Measurements

1 – PISTON O.D. MEASUREMENT LOCATION

Fig. 16 Piston Ring Gap

1 – FEELER GAUGE

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2.0L SOHC ENGINE

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SERVICE PROCEDURES (Continued)

the oil hole. In addition, suspect areas can be
checked by placing plastigage in that area.

(4) Assemble the rod cap with Plastigage in place.

Tighten the rod cap to the specified torque. Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.

(5) Remove the bearing cap and compare the width

of the flattened Plastigage with the scale provided on
the package (Fig. 18). Locate the band closest to the
same width. This band indicates the amount of oil
clearance. Differences in readings between the ends
indicate the amount of taper present. Record all
readings taken. Refer to Engine Specifications. Plas-
tigage generally is accompanied by two scales.
One scale is in inches, the other is a metric
scale. If the bearing clearance exceeds wear
limit specification, replace the bearing.

NOTE: The rod bearing bolts should not be reused.

(1) Before installing the NEW bolts the threads

should be oiled with clean engine oil.

(2) Install each bolt finger tight than alternately

torque each bolt to assemble the cap properly.

(3) Tighten the bolts to 27 N·m PLUS 1/4 turn (20

ft. lbs. PLUS 1/4 turn) Do not use a torque
wrench for last step.

(4) Using a feeler gauge, check connecting rod side

clearance (Fig. 19). Refer to Engine Specifications in
this section for connecting rod specifications.

CRANKSHAFT MAIN BEARING—FITTING

PLASTIGAGE PROCEDURE

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
holes (Fig. 20). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap 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 pro-
vided on the package. Locate the band closest to the
same width. This band shows the amount of clear-
ance in thousandths of a millimeter. Differences in
readings between the ends indicate the amount of
taper present. Record all readings taken. Refer to
Engine

Specifications.

Plastigage

generally

is

accompanied 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.

Fig. 17 Piston Ring Side Clearance

1 – FEELER GAUGE

Fig. 18 Connecting Rod Bearing Clearance—Typical

Fig. 19 Connecting Rod Side Clearance

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2.0L SOHC ENGINE

9 - 19

SERVICE PROCEDURES (Continued)

(4) Install the proper crankshaft main bearings to

achieve the specified bearing clearances. Refer to
Crankshaft, Removal and Installation procedure.

CRANKSHAFT END PLAY

DIAL INDICATOR METHOD

(1) Mount a dial indicator to front of engine, locat-

ing probe on nose of crankshaft (Fig. 21).

(2) Move crankshaft all the way to the rear of its

travel.

(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front of its

travel and read the dial indicator. Refer to Engine
Specifications in this section for crankshaft specifica-
tions.

FEELER GAGE METHOD

(1) Move crankshaft all the way to the rear of its

travel using a lever inserted between a main bearing
cap and a crankshaft cheek, using care not to dam-
age any bearing surface. Do not loosen main bearing
cap.

(2) Use a feeler gauge between number three

thrust bearing and machined crankshaft surface to
determine end play.

CAMSHAFT END PLAY

(1) Oil camshaft journals and remove rocker arm

assemblies.

Cam

sensor

installed

and

fastener

tighten to specified torque.

(2) Using a suitable tool, move camshaft as far

rearward as it will go.

(3) Zero dial indicator (Fig. 22).
(4) Move camshaft as far forward as it will go.
(5) Refer to Engine Specification for camshaft end

play specifications.

REMOVAL AND INSTALLATION

ENGINE MOUNTS—FRONT AND REAR

REMOVAL

FRONT MOUNT

(1) Raise vehicle on hoist.
(2) Remove through bolt at front mount (Fig. 25).
(3) Remove attaching bolts from mount to lower

radiator support.

NOTE: It may be necessary to tilt engine for front
mount removal clearance.

(4) Remove front mount.

Fig. 20 Plastigage Placed in Lower Shell—Typical

1 – PLASTIC GAUGE

Fig. 21 Checking Crankshaft End Play— Dial

Indicator

Fig. 22 Camshaft End Play

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SERVICE PROCEDURES (Continued)