Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Cylinder Head

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Precautions




NOTE
Before servicing the vehicle, also refer to the precautions in the beginning of this section.

Removal & Installation




NOTE
The cylinder head bolts should be checked for stretching before reuse. If the thread area of the bolt is necked-down the bolts must be replaced with new. New head bolts are recommended.



Click image to see an enlarged view

Fig. Before reusing old cylinder head bolts, check them for necking (stretching)-2.4L engine

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    All vacuum hoses, lines and wiring harness connections required for cylinder head removal
     
    Fuel line
     
    Throttle linkage
     
    Accessory drive belt(s)
     
    Power steering pump and move aside
     
    Coil pack wiring connector
     
    Spark plug wires from the spark plugs
     
    Ignition coil pack unit
     
    Cylinder head cover
     
    Intake and exhaust manifolds, if necessary
     
    Timing belt cover, timing belt, camshaft sprocket and rear timing belt cover
     
    Rocker arm/rocker arm shaft assemblies
     
    Cylinder head bolts and cylinder head
     

  10.  

To install:

Click image to see an enlarged view

Fig. Checking the cylinder head bolts for necking (stretching)-2.0L engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.0L engine


WARNING
Stretch-type bolts are used. New head bolts are recommended.

  1. Thoroughly clean all parts. Clean all sealing surfaces. Use care not to scratch the aluminum cylinder head sealing surface. Check the cylinder head for flatness using a feeler gauge and a straight-edge. The cylinder head must be flat within 0.004 in. (0.1mm).
  2.  
  3. Check the cylinder head for cracks or other damage.
  4.  
  5. Install a new gasket and the cylinder head.
  6.  
  7. Lubricate the cylinder head bolt threads with clean engine oil.
  8.  
  9. Install the cylinder head bolts, the short bolts (110mm) are to be installed in positions 7, 8, 9 and 10.
  10.  
  11. Torque the cylinder head bolts in 4 steps as follows:
    1. Step 1: 25 ft. lbs. (34 Nm).
    2.  
    3. Step 2: 50 ft. lbs. (68 Nm).
    4.  
    5. Step 3: Again to 50 ft. lbs. (68 Nm).
    6.  
    7. Step 4: Plus 1 / 4 (90 degree) turn.
      NOTE
      Do not use a torque wrench for the 4th step.

    8.  

  12.  
  13. Install or connect the following:

    Rocker arm/rocker arm shaft assemblies
     
    Cylinder head cover
     
    Timing belt rear cover, camshaft sprocket and timing belt
     
    Timing belt cover
     
    Intake and exhaust manifolds, if removed
     
    Ignition coil pack
     
    Coil pack wiring connector and spark plug wires
     
    Power steering pump
     
    Accessory drive belts
     
    Throttle linkage
     
    All ducts, hoses, fuel lines and wiring harness connectors
     
    Air cleaner assembly
     
    Negative battery cable
     

  14.  
  15. Fill the cooling system.
    NOTE
    A complete oil and filter change is recommended.

  16.  
  17. Start the engine and check for leaks. Run the engine with the radiator cap off so as the engine warms and the thermostat opens, coolant can be added to the radiator. When the cooling system is full, shut the engine OFF , install the radiator cap and allow the engine to cool.
  18.  
  19. With the engine cool, check all fluid levels. Add coolant and oil as required. Restart the engine and test drive vehicle to check for proper operation.
  20.  

This engine uses a Single Over Head Camshaft (SOHC) 4-valves per cylinder cross flow aluminum cylinder head. Care must be taken to be sure all valve timing marks align after cylinder head service.

Click image to see an enlarged view

Fig. Exploded view of the cylinder head and valve train components-2.0L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure.
  4.  
  5. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Air cleaner assembly
     
    All vacuum hoses and electrical connectors from the throttle body
     
    Fuel line quick-connect fitting from the fuel rail, by squeezing the retainer tabs together and pulling the fuel tube/quick-connect fitting assembly off the fuel tube nipple
     
    Throttle linkage
     
    Accessory drive belt(s)
     
    Power brake booster vacuum hose from the intake manifold
     
    Exhaust pipe from the exhaust manifold
     
    Power steering pump and move it aside
     
    Coil pack wiring connector
     
    Spark plug wires from the spark plugs
     
    Ignition coil pack
     
    Cylinder head cover
     
    Cam sensor and fuel injector wiring
     
    Intake and exhaust manifolds, if necessary
     
    Timing belt cover
     
    Timing belt
     
    Camshaft sprocket
     
    Rear timing belt cover
     
    Rocker arm/rocker arm shaft assemblies
     
    Cylinder head bolts
     
    Cylinder head
     

  10.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.0L engine


NOTE
The cylinder head bolts should be checked for stretching before reuse. If the thread area of the bolt is necked-down the bolts must be replaced with new. New head bolts are recommended.

  1. Thoroughly clean all parts. Clean all sealing surfaces. Use care not to scratch the aluminum cylinder head sealing surface. Check the cylinder head for flatness using a feeler gauge and a straightedge. The cylinder head must be flat within 0.004 inch (0.1mm).
  2.  
  3. Check the cylinder head for cracks or other damage.
  4.  
  5. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     

  6.  
  7. Be sure to oil the cylinder head bolt threads with clean engine oil. Install the cylinder head bolts, the 4.330 inch (110mm) short bolts are to be installed in positions 7, 8, 9 and 10. Tighten the bolts in proper sequence.
  8.  
  9. Torque the cylinder head bolts, in sequence, using the following steps:
    1. Step 1: 25 ft. lbs. (34 Nm).
    2.  
    3. Step 2: 50 ft. lbs. (68 Nm).
    4.  
    5. Step 3: again to 50 ft. lbs. (68 Nm).
    6.  
    7. Step 4: an additional 1 / 4 turn.
      NOTE
      Do not use a torque wrench for the 4th step.

    8.  

  10.  
  11. Set the crankshaft to 3 notches Before Top Dead Center (BTDC) before installing the rocker arm shafts.
  12.  
  13. Install or connect the following:
    NOTE
    Be sure the cover gasket mating surfaces are clean of any dirt, oil or old gasket material.



    Rocker arm/rocker arm shaft assemblies
     
    Cylinder head cover using a new gasket. Torque the bolts to 105 inch lbs. (12 Nm).
     



    Timing belt rear cover
     
    Camshaft sprocket
     
    Timing belt
     
    Timing belt cover
     
    Intake and exhaust manifolds, if removed
     
    Cam sensor and fuel injector electrical connectors
     
    Ignition coil pack
     
    Spark plug wires
     
    Power steering pump
     
    Exhaust pipe to the exhaust manifold
     
    Brake booster vacuum line
     
    Accessory drive belts and adjust them
     
    Throttle linkage
     
    All vacuum hoses and electrical connectors to the throttle body
     
    Fuel line to the fuel rail
     
    Air cleaner assembly
     
    Negative battery cable
     

  14.  
  15. Refill the cooling system and install the a new oil filter.
  16.  
  17. Check to be sure all ducts, hoses, fuel lines and wiring connectors have been properly reattached.
  18.  
  19. Start the engine and check for leaks. Run the engine with the radiator cap off so as the engine warms and the thermostat opens, coolant can be added to the radiator. When satisfied that the cooling system is full, shut the engine OFF , install the radiator cap and allow the engine to cool.
  20.  
  21. With the engine cool, check all fluid levels. Add coolant and oil as required. Restart the engine and test drive the vehicle to check for proper operation.
  22.  

2.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt and camshaft sprockets
     
    Wiring harnesses, vacuum hoses and lines that may inhibit cylinder head removal
     
    Intake manifold assembly
     
    Water pump inlet pipe retaining bolt from the inner rear of the front cylinder head
     
    Valve covers and rocker arm assemblies
     
    Distributor assembly
     
    Ground strap from the left end of the front cylinder head
     
    Exhaust manifolds and crossover pipe
     
    Cylinder head bolts; keep them in numbered order
     
    Cylinder head and discard the gasket
     

  8.  

To install:

Click image to see an enlarged view

Fig. Install the head gasket with the identification mark at the front facing upward-2.5L engine



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.5L engine

  1. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean the oil passages thoroughly. Check the head for flatness. End-to-end, the head should be no more than 0.008 in. (0.2mm) out-of-true. If the service limit is exceeded, correct to meet specifications. Note that the maximum amount from stock allowed to be removed from the cylinder head and mating cylinder block is 0.0079 in. (0.2mm). If the cylinder head cannot be made serviceable by removing this amount, replace it.
  2.  
  3. Check that the head gaskets have the proper identification marks for the engine. Lay the head gasket with the identification mark at the front top.
    NOTE
    Do not apply sealant to the head gasket or mating surfaces. Stretch-type cylinder head bolts are used. All new head bolts are recommended.

  4.  
  5. Install the cylinder head straight down onto the block.
  6.  
  7. Lubricate the bolts with clean engine oil.
  8.  
  9. Install the bolts and the special washers by hand and just start each bolt one or 2 turns on the threads.
    NOTE
    The washers must be installed correctly. The rounded shoulder of the washer denotes the face in contact with the bolt. The flat side of the washer contacts the head.

  10.  
  11. Torque the head bolts in the proper sequence as follows:
    1. Step1: 62 ft. lbs. (84 Nm).
    2.  
    3. Step 2: 70 ft. lbs. (95 Nm).
    4.  
    5. Step 3: 80 ft. lbs. (108 Nm).
    6.  

  12.  
  13. Install or connect the following:

    Valve cover and gasket
     
    Exhaust manifolds and crossover pipe
     
    Distributor
     
    Intake manifold
     
    All wiring harnesses, vacuum hoses and lines
     
    Negative battery cable
     

  14.  
  15. Fill the cooling system. Changing the oil and filter is recommended to eliminate pollutants such as coolant in the oil.
  16.  
  17. With the radiator cap off, start the engine and check for leaks of fuel, vacuum, oil or coolant. Check the operation of all engine electrical systems as well as dashboard gauges and lights. Add coolant as the engine warms.
  18.  
  19. Perform necessary adjustments to the accelerator cable and drive belts. Allow the engine to cool and once again check and adjust the coolant level.
  20.  

This engine uses aluminum alloy cylinder heads with 4-valves per cylinder and pressed-in cast iron valve guides. The cylinders are common to either cylinder bank. Two overhead camshafts are supported by 4 bearing journals which are part of the head with the distributor driven off the right (firewall side) cylinder head. Right and left camshaft drive sprockets are interchangeable. The sprockets and engine water pump are driven by the timing belt. Care must be taken to be sure all valve timing marks align after cylinder head and valve train service.


NOTE
Please note that for camshaft service, the cylinder head must be removed.



Click image to see an enlarged view

Fig. Exploded view of the cylinder head, camshafts and rocker assemblies-2.5L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  4.  
  5. Relieve the fuel system pressure using the recommended procedure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:
    NOTE
    The intake manifold is a 2-piece unit. The upper part is a large air intake plenum of aluminum alloy. Use care working with light alloy parts.



    Accessory drive belts
     
    Front timing belt covers
     
    Timing belt
     
    Camshaft sprockets
     



    Air intake plenum
     
    Manifold Absolute Pressure (MAP) and Intake Air Temperature (IAT) sensor wiring connectors
     
    Air cleaner cover, inlet hoses and air inlet resonator
     
    Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor electrical connectors
     
    Throttle cable
     
    Speed control cable (if equipped)
     
    Exhaust Gas Recirculation (EGR) tube
     
    Lower intake manifold
     
    Spark plug wires and move them aside
     
    Cylinder head cover
     

  10.  
  11. Identify the rocker arm shaft assemblies before removal.
  12.  
  13. Install the Auto Lash Adjuster Retainers MD 998443, to keep the auto lash adjusters from falling out of the rocker arms when the rocker arm assembly is removed.
  14.  
  15. Remove or disconnect the following:

    Rocker arm shaft assemblies
     
    Distributor assembly
     
    Exhaust manifold and crossover
     
    Cylinder head bolts
     
    Cylinder head
     

  16.  
  17. If the camshaft(s) are to be serviced, remove the thrust case from the left head assembly and remove the camshaft from the rear of the head. If not already done, remove the distributor from the right cylinder head and remove the camshaft from the rear of the head.
  18.  
  19. Valve service may be performed at this time, if required.
  20.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.5L engine

  1. Thoroughly clean all parts well. All sealing surfaces on the engine block, cylinder head(s) and both the upper and lower sections of the intake manifold must be clean. Check for cracks, signs of wear in the camshaft bores or other damage. With a straightedge and feeler gauge, check the head for flatness. It should be within 0.0012 inch (0.03mm) along its length. The service limit is 0.008 inch (0.2mm). If the head must be resurfaced, the grinding limit is 0.008 inch (0.2mm). Note that this dimension is a combined total dimension of stock material removal from the cylinder head, if any, and the block top surface is 0.0079 inch (0.2mm).
  2.  
  3. Camshaft end-play can be checked as follows:
    1. Oil the camshaft journals with clean engine oil and install the (if removed) the camshaft without the rocker arm assemblies.
    2.  
    3. Move the camshaft as far rearward as it will go.
    4.  
    5. Mount a dial indicator to bear on the front of the camshaft.
    6.  
    7. Zero the indicator.
    8.  
    9. Move the camshaft as far forward as it will go. End-play should be 0.004-0.008 inch (0.1-0.2mm). Maximum allowed end-play is 0.016 inch (0.4mm).
    10.  

  4.  
  5. If the camshafts were removed, lubricate the camshaft journals and carefully reinstall the camshaft into the cylinder head. Install the thrust case and torque the thrust case mounting bolts to 108 inch lbs. (13 Nm).
  6.  
  7. Apply a light coating of engine oil to the lip of the camshaft seal(s).
    NOTE
    Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

  8.  
  9. Install or connect the following:

    Camshaft seal(s)
     
    Camshaft sprocket(s) and torque the bolts to 65 ft. lbs. (88 Nm)
     
    New cylinder head gasket
     
    Cylinder head
     
    New 10mm Allen hex cylinder head bolts, with washers. Torque the cylinder head bolts, in proper sequence, in 2-3 steps, to 80 ft. lbs. (108 Nm).
     
    Lower intake manifold using new gaskets
     
    Rocker arm assemblies
     
    Exhaust manifold and crossover exhaust pipe
     
    Timing belt, properly align the timing marks
     
    Timing belt covers
     

  10.  
  11. Inspect the spark plug tube seals located on the ends of each tube. These seals slide onto each tube to seal the cylinder head cover to the spark plug tube. If these seals show signs of hardness and/or cracks, they should be replaced.
  12.  
  13. Thoroughly clean all sealing surfaces.
  14.  
  15. Remove or disconnect the following:

    Cover using a new gasket. Torque bolts to 88 inch lbs. (10 Nm).
     
    Distributor assembly
     
    Spark plug wires
     
    Upper intake manifold (plenum) using a new gasket. Torque the bolts to 13 ft. lbs. (18 Nm).
     
    Plenum support bracket bolts
     
    EGR tube
     
    Speed control cable (if equipped)
     
    Throttle cable
     
    TPS and IAC motor electrical connectors
     
    Air cleaner cover, inlet hoses and air inlet resonator
     
    MAP and IAT sensor wiring connectors
     
    Accessory drive belts and adjust them
     
    Negative battery cable
     

  16.  
  17. Refill the cooling system.
    NOTE
    An oil and filter change is recommended whenever a cylinder head has been removed since coolant can get into the oil system.

  18.  
  19. Check to be sure all ducts, hoses, fuel lines and wiring connections have all been properly reattached.
  20.  
  21. Start the engine and check for leaks, abnormal noises and vibrations. Bleed the cooling system.
  22.  

2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Drive belts
     
    Vibration damper
     
    Exhaust cross under pipe
     
    Catalytic converter
     
    Upper and lower intake manifolds
     
    Rocker arm covers
     
    Water outlet connector and rotate the crankshaft until the sprocket timing mark aligns with the timing mark on the oil pump housing
     
    Primary timing chain
     
    Camshaft bearing caps gradually
     
    Camshafts and valve train components
     
    Cylinder head and discard the gasket
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.7L engine

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Lubricate the threads of the cylinder head bolts with clean engine oil.
  4.  
  5. Install or connect the following:

    Cylinder head with a new gasket
     

  6.  
  7. Torque the bolts, in sequence, using the following procedure:
    1. Step 1: Bolts 1-8: 35 ft. lbs. (48 Nm).
    2.  
    3. Step 2: Bolts 1-8: 55 ft. lbs. (75 Nm).
    4.  
    5. Step 3: Bolts 1-8: 55 ft. lbs. (75 Nm).
    6.  
    7. Step 4: Bolts 1-8: An additional 90°. Do not use a torque wrench for this step.
    8.  
    9. Step 5: Bolts 9-11: 21 ft. lbs. (28 Nm).

      Valve train components and the camshafts
       
      Timing chain and sprockets
       
      Water outlet connector
       
      Rocker arm covers
       
      Timing chain cover
       
      Crankshaft vibration damper
       
      Lower and upper intake manifolds
       
      Catalytic converter
       
      Exhaust cross under pipe
       
      Drive belts
       
      Negative battery cable
       

    10.  

  8.  
  9. Fill the cooling system to the proper level.
  10.  
  11. Start the vehicle, check for leaks and repair if necessary.
  12.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Alternator
     
    Intake manifold
     
    Exhaust manifold
     
    Water inlet pipe
     
    Breather and blow by hoses
     
    Positive Crankcase Ventilation (PCV) hose
     
    Spark plug cables
     
    Rocker arm cover
     
    Timing belt rear cover
     
    Cylinder head and discard the gasket
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.0L engine

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Lubricate the threads of the cylinder head bolts with clean engine oil.
  4.  
  5. Install or connect the following:

    Cylinder head with a new gasket
     

  6.  
  7. Torque the bolts, in sequence, as follows:
    1. Step 1: 80 ft. lbs. (108 Nm).
    2.  
    3. Step 2: Loosen all bolts in sequence.
    4.  
    5. Step 3: 80 ft. lbs. (108 Nm).
    6.  

  8.  
  9. Install or connect the following:

    Rear timing belt cover
     
    Rocker arm cover
     
    Spark plug cables
     
    PCV and blow by hoses
     
    Breather hose
     
    Water inlet pipe
     
    Exhaust manifold
     
    Intake manifold
     
    Alternator
     
    Timing belt
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system to the proper level.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

 
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