Avenger 2008

Camshaft, Bearings & Lifters

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Inspection



  1. Inspect camshaft bearing journals for damage. If journals are damaged, check the cylinder head for damage. Also check cylinder head oil holes for clogging.
  2.  
  3. Check the cam lobe and bearing surfaces for abnormal wear and damage. Replace camshaft if defective.
    NOTE
    If camshaft is replaced due to lobe wear or damage, always replace the lash buckets.

  4.  

Removal & Installation



2.4L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Remove engine cover (1) by pulling upward.

    Click image to see an enlarged view

    Fig. Remove engine cover (1) by pulling upward

  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Remove cylinder head cover.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the frame cover portion of the right splash shield.
  10.  
  11. Rotate engine to TDC (1).

    Click image to see an enlarged view

    Fig. Rotate engine to TDC (1)

  12.  
  13. Make sure camshaft timing marks (3) are in line with the cylinder head cover sealing surface.

    Click image to see an enlarged view

    Fig. Make sure camshaft timing marks (3) are in line with the cylinder head cover sealing surface

  14.  
  15. Mark the chain link corresponding to timing marks (1) with a paint marker.
  16.  
  17. Remove timing tensioner plug (1) from front cover.

    Click image to see an enlarged view

    Fig. Remove timing tensioner plug (1) from front cover

  18.  
  19. Insert small Allen wrench through timing tensioner plug hole and lift ratchet (2) upward to release the tensioner and push Allen wrench inward. Leave the Allen wrench installed during the remainder of this procedure.

    Click image to see an enlarged view

    Fig. Insert small Allen wrench through timing tensioner plug hole and lift ratchet (2) upward to release the tensioner and push Allen wrench inward

  20.  
  21. Insert Locking Wedge 9701 (1) between camshaft phasers.

    Click image to see an enlarged view

    Fig. Insert Locking Wedge 9701 (1) between camshaft phasers

  22.  
  23. Lightly tap Locking Wedge 9701 (2) into place until it will no longer sink down.
    NOTE
    Camshaft bearing caps should have been marked during engine manufacturing. For example, number one exhaust camshaft bearing is marked "E1>".


    CAUTION
    DO NOT use a number stamp or a punch to mark camshaft bearing caps. Damage to bearing caps could occur.



    Click image to see an enlarged view

    Fig. Lightly tap Locking Wedge 9701 (2) into place until it will no longer sink down



    Click image to see an enlarged view

    Fig. Camshaft bearing caps should have been marked during engine manufacturing

  24.  
  25. Using a permanent ink or paint marker, identify location and position on each camshaft bearing cap.
  26.  
  27. Remove the front camshaft bearing cap.
  28.  
  29. Slowly remove the remaining intake and exhaust camshaft bearing cap bolts one turn at a time.
  30.  
  31. Remove intake camshaft (1) by lifting the rear of the camshaft upward.

    Click image to see an enlarged view

    Fig. Remove intake camshaft (1) by lifting the rear of the camshaft upward

  32.  
  33. Rotate the camshaft while lifting out of the front bearing cradle.

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    Fig. Rotate the camshaft while lifting out of the front bearing cradle

  34.  
  35. Lift the timing chain (2) off the sprocket (1).

    Click image to see an enlarged view

    Fig. Lift the timing chain (2) off the sprocket (1)

  36.  
  37. Remove exhaust camshaft.
  38.  
  39. Secure timing chain with wire so that it does fall into the timing chain cover.
  40.  

To install:

  1. The front camshaft bearing cap (1) is numbered (2) either one, two, or three, this corresponds to the select fit front exhaust camshaft bearing to use.

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    Fig. The front camshaft bearing cap (1) is numbered (2) either one, two, or three

  2.  
  3. Install the corresponding select fit front exhaust camshaft bearing (1).

    Click image to see an enlarged view

    Fig. Install the corresponding select fit front exhaust camshaft bearing (1)

  4.  
  5. Oil all of the camshaft journals with clean engine oil.
  6.  
  7. Install camshaft phasers on camshafts if removed.
  8.  
  9. Install timing chain onto exhaust cam sprocket making sure that the timing marks on the sprocket and the painted chain link are aligned.
  10.  
  11. Position exhaust camshaft and on bearing journals in the cylinder head.
  12.  
  13. Align exhaust cam timing mark so it is in line with the cylinder head cover sealing surface.
  14.  
  15. Install intake camshaft by raising the rear of the camshaft upward and roll the sprocket into the chain.
  16.  
  17. Align the timing marks on the intake cam sprocket with the painted chain link.
  18.  
  19. Position the intake camshaft into the bearing journals in the cylinder head.
  20.  
  21. Verify that the timing marks are aligned on both camshafts and that the timing marks are facing each other and are in line with the cylinder head cover sealing surface.
    CAUTION
    Install the front intake and exhaust camshaft bearing cap last. Ensure that the dowels are seated and follow torque sequence or damage to engine could result.


    NOTE
    If the front camshaft bearing cap is broken, the cylinder head MUST be replaced.

  22.  
  23. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 85 inch lbs. (9.5 Nm) in the sequence shown.
    NOTE
    Verify that the exhaust bearing shells are correctly installed, and the dowels are seated in the head, prior to torquing bolts.



    Click image to see an enlarged view

    Fig. Install intake and exhaust camshaft bearing caps in the sequence shown

  24.  
  25. Install the front intake and exhaust bearing cap and tighten bolts to 18 ft. lbs. (25 Nm) in the sequence shown.

    Click image to see an enlarged view

    Fig. Install the front intake and exhaust bearing cap in the sequence shown

  26.  
  27. Verify that all timing marks are aligned.
  28.  
  29. Remove Allen wrench from timing chain tensioner.
  30.  
  31. Remove Locking Wedge 9701 by pulling straight upward on pull rope.
  32.  
  33. Apply MOPAR® thread sealant to timing tensioner plug and Install.
  34.  
  35. Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the TDC position.
  36.  
  37. Verify that the camshafts timing marks are in the proper position and in line with the cylinder head cover sealing surface. If the marks do not line up, the timing chain is not correctly installed.
  38.  
  39. Install right splash shield.
  40.  
  41. Remove RTV from gasket.
  42.  
  43. Inspect cylinder head cover gaskets for damage. If no damage is present, gaskets can be re-installed.
  44.  
  45. Install cylinder head cover.

    Click image to see an enlarged view

    Fig. Install cylinder head cover and tighten in sequence

  46.  
  47. Connect negative battery cable.
  48.  
  49. Fill cooling system.
  50.  
  51. Fill with oil.
  52.  
  53. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for correct fluid levels.
  54.  
  55. Install engine cover.
  56.  

2.7L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Remove the primary timing chain.
  2.  
  3. Remove secondary chain tensioner mounting bolts.
    NOTE
    Camshaft bearing caps should have been marked during engine manufacturing. For example, number one exhaust camshaft bearing is marked -1E>-

  4.  
  5. Slowly loosen camshaft bearing cap bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Loosen camshaft bearing cap bolts in the sequence shown

  6.  
  7. Remove camshaft bearing caps (1).
  8.  
  9. Remove intake camshaft (7), exhaust camshaft (2), secondary timing chain (8), and secondary timing chain tensioner (6) together as an assembly.
  10.  
  11. Remove secondary timing chain tensioner (6) and secondary timing chain (8) from camshafts (2) and (7).
  12.  
  13. Inspect camshafts.

    Click image to see an enlarged view

    Fig. Exploded view of engine camshaft system components

  14.  

To install:


CAUTION
When the timing chain is removed and the cylinder heads are installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.

  1. Assemble camshaft chain on the cams. Verify that plated links (1) are facing toward the front. Align the plated links (1) to the dots (4) on the camshaft sprockets.

    Click image to see an enlarged view

    Fig. Verify that plated links (1) are facing toward the front

  2.  
  3. If camshaft chain tensioner is already in the compressed and locked position, proceed to step four.
  4.  
  5. When the camshaft chain tensioner is removed, it is necessary to compress and lock the tensioner using the following procedures:

    Click image to see an enlarged view

    Fig. Place tensioner (1) into a soft jaw vise

    1. Place tensioner (1) into a soft jaw vise.
    2.  
    3. SLOWLY compress tensioner until fabricated lock pin (2) or the equivalent can be inserted into the locking holes.
    4.  
    5. Remove compressed and locked tensioner from the vise.
    6.  

  6.  
  7. Insert the compressed and locked camshaft chain tensioner (2) in between the camshafts and chain.

    Click image to see an enlarged view

    Fig. Insert the compressed and locked camshaft chain tensioner (2) in between the camshafts and chain

  8.  
  9. Rotate the cams so that the plated links (1) and dots (4) are facing the 12:00 o'clock position.
  10.  
  11. Install cams to cylinder head. Verify that rocker arms are correctly seated and in proper positions.
  12.  
  13. Install camshaft bearing caps. Verify that bearing caps are installed in same position as removed.
  14.  
  15. Tighten cam bearing cap bolts gradually in sequence shown. Tighten to 105 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Tighten cam bearing cap bolts gradually in sequence shown

  16.  
  17. Install secondary chain tensioner bolts and tighten to 105 inch lbs. (12 Nm).
  18.  
  19. Remove locking pin (3) from secondary tensioners (2).

    Click image to see an enlarged view

    Fig. Remove locking pin (3) from secondary tensioners (2)

  20.  
  21. Verify end play of camshafts are within specification.
  22.  
  23. Install the primary timing chain.
  24.  

3.5L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


NOTE
Camshafts are removed from the rear of each cylinder head.



Click image to see an enlarged view

Fig. Camshafts are removed from the rear of each cylinder head


CAUTION
Care must be taken not to nick or scratch the journals when removing the camshaft.

  1. Remove the camshaft sprocket.
  2.  
  3. Remove the rocker arm shaft assembly.
  4.  
  5. To remove the right camshaft, remove the EGR Valve assembly.
  6.  
  7. Remove the camshaft thrust plate (1) or (2).

    Click image to see an enlarged view

    Fig. Remove the camshaft thrust plate (1) or (2)

  8.  
  9. Carefully remove the camshaft from the rear of the cylinder head.
    NOTE
    It may be necessary to remove the Powertrain Control Module (PCM) in order to remove the camshaft from the right cylinder head.

  10.  

To install:

  1. Lubricate camshaft bearing journals, camshaft lobes and camshaft seal with clean engine oil and install camshaft into cylinder head.
  2.  
  3. Install the camshaft sprocket.
  4.  
  5. Install the camshaft thrust plate. Clean the mating surfaces and apply the appropriate sealer as necessary. Torque fasteners to 21 ft. lbs. (28 Nm).
  6.  
  7. If necessary, install the EGR Valve assembly and Powertrain Control Module (PCM).
  8.  
  9. Install the rocker arm assembly.
  10.  

 
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