6-13 Chrysler:Layout 1 - Engine Builder Magazine
Contents
1. Fix is a Snap for 2 0L 2 4L Chrysler Engines with High Pitched Noise A strange noise may cause concern to owners of some Chrysler vehicles particu larly 2001 2004 vehicles equipped with a 2 0L 2 4L DOHC or 2 4L Turbo engine The noise may occur when the vehicle is in park and the engine is running between idle and 1 400 rpm at normal operating temperature The sound is heard at the upper end of the engine cylinder head toward the right front side passenger side and is irregular not periodic or har monious The frequency of the noise will increase with rpm The sound is more of a high pitched snapping noise than a low metallic knock If the customer describes the noise and the installer determines that the sound is coming from the described location the repair procedure involves chamfering the bore radius on cam bearing caps L2 through L5 and R2 through R5 Before beginning the repair review safety procedures in ALL DATA Repair 1 Remove the cylin der head cover 2 Remove L2 cam bearing cap see Figure 1 Note Do not remove the L1 R1 or L6 cam bearing caps or loosen the fasteners Only remove one cam bearing cap at a time 3 Lightly chamfer the two bore radius edges with a small hand file creating a 45 cham fer 1 0 to 1 5 mm in width along the edge of each bore radius see Figure 2 Caution Be careful not to scratch the bore surface of the cam bearing cap s Chamfer both bore radii2. Some outer exhaust manifold exhaust studs are breaking due to fatigue on 1991 1999 Jeep 2 5L engines Inspect either manifold Figure 4 Replace both outer mounting studs clamps and nuts on Jeep 2 5L engines with new parts and tighten the outer studs to a reduced torque of 180 in lbs stud for breakage and if breakage is noted perform the repair procedure outlined below Models engines 1996 1999 AN Dakota 1991 1992 MJ Comanche 1997 1999 TJ Wrangler 1991 1999 XJ Cherokee 1991 1995 YJ Wrangler NOTE This information applies to Jeep vehicles equipped with a 2 5L engine This procedure involves replacing both outer mounting studs clamps and nuts with new parts and tightening the outer studs to a reduced torque of 180 in lbs 20 Nm 1 Remove the intake exhaust manifold per service manual procedures to gain access to the broken stud s 2 Remove the outer studs from the cylinder head Use a stud removal tool if possible or drill the broken stud from the head 3 Install two new outer studs p n 06036193AA into the cylinder block Torque the studs to 126 in lbs 14 Nm 4 Clean any carbon deposits or debris from the exhaust manifold 5 Reinstall the exhaust manifold Use only the new studs listed above to attach the outer ends 6 Torque the bolts in the order and specification as listed in Figure 4 affected with 2 5L Cylinder Head Oil Gallery Cup Plug Service for Chrysler 2 7L En
3. the yellow roloc bristle disk 3m p n 07525 can be used Use extreme care when power cleaning aluminum surfaces 50 Cash Back with the purchase of any 8 cylinder set of SRP or SRP Professional Pistons WWW n ort n CO mn rehate Rings included with SAP Professional sets 15312 Connector Lane Huntington Beach CA 92649 714 898 9763 srp com Circle 108 for more information 8 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2010 to prevent metal transfer 6 Inspect the sealing surfaces for any remaining composite gasket residue Carefully remove any remaining material 7 The head and block must be checked for flatness Follow appropriate service manual procedures specifications where applicable 8 Spray both sides of the MLS gasket with a coat of MOPAR spray gasket sealant p n 0431 8035 9 Re assemble the engine as outlined in the appropriate service manual Pay par ticular attention to head bolt torque and torque procedures All head bolts should be oiled prior to assembly Note torque and torqueing procedure has changed when installing an MLS gasket on the 2 0L DOHC Use the following procedures for the 2 0L DOHC only 10 Make sure the cam sensor seal 1s replaced on all engine applications Note A new cam sensor seal must be installed during the head gasket replace ment procedure Oil seepage from this seal can be misinterpreted as a head gasket leak 11 Replace the engine oil and filter after pe
4. 0 Figure 1 Remove cylinder head valve cover on Chrysler 2 0L and 2 4L engines then remove L2 cam bearing cap loosely assembling the fasteners Prior to and during the torquing of each fastener twist the cam bearing cap by hand in a clockwise direction as viewed from the top of the engine Torque M6 fasteners to 105 in Ibs 12 Nm while maintaining a clock wise twisting force on the cam bearing cap 6 Repeat steps 2 through 4 for cam bearing caps L3 L4 L5 R2 R3 R4 R5 and R6 7 Reinstall the cylinder head cover 8 Verify the repair Bulletin contributed by Eric Seifert ALL DATA Automotive Technical Editor MLS Head Gasket Installation Procedures for Chrysler 2 0L and 2 4L The MLS gasket was released for produc tion as a running change in the 1999 model year for all models except FJ The new gasket provides superior sealing char acteristics but will require extra care in their installation where a composite gasket was previously in place Caution Aluminum engine compo nents are susceptible to metal transfer and surface damage when old gasket material is removed from them Use extreme care when cleaning gasket material from alu Figure 2 Lightly chamfer bore radius edges on 2 0L 2 4L engines with a hand file creating a 45 chamfer along the edge of each bore radius CHR YS LE R a 3E LOCATION OF 110 mm 4 330 In BOLTS Figure 3 Torque sequence for 2 0L DOHC with MLS gasket installation T
5. 30 F 110 C Use the digital display located in the instru ment cluster for oil temperature 2 Allow the engine to stabilize at idle and read the oil pressure using the digital display located in the instru ment cluster 3 Shut the engine off and wait 10 sec onds 4 Restart the engine with NO throttle application allow the engine to settle at idle RPM 5 Note the oil pressure as it may read 1 to 2 psi less than in step 2 If this is the case the whine may be heard If the procedure is followed closely the whine can be turned on and off with a slight change to oil pres sure The piston cooling jets see Figure 9 are operating properly but high oil temper ature results in slightly lower operating oil pressure at idle and can cause the valve inside the oil cooler jets to flutter Figure 9 A whine sound may be present at idle after vehicles with 6 1L Hemi engines have been driven in warm ambient tempera tures over 50 F 10 C This sound can be caused by the piston oil cooler jets fluttering during hot oil idle conditions If a customer complains about this sound first reassure him or her that no detrimental effect on engine durability is caused by the jets fluttering If the customer wants this noise eliminated Chrysler rec ommends the use of 15W50 Mobil One engine oil in warmer summer months and revert back to OW40 Mobile One engine oil in cooler months If the oil vis cosity is changed a labe
6. 4 Clean the part to remove any alu minum filings prior to reinstalling 5 Reinstall the L2 cam bearing cap by The Best Solutions are available from Engine amp Performance Warehouse Now order online at www epwi net with KIT WIZARD Traditional quality meets high technology Ordering online is as easy as 1 b ust click on Engine Kits the vehic aac type of kit oversizes amp unders add to order and you re done 2 3 24 71 le make amp your kit number izes amp warranty option in as little as 30 seconds Getting the best engine kits and parts in the business Is now even faster anytime Find out more at www epwi net or call an EPWI branch warehouse convenient to you KIT WIZARD is the newest customer convenience and it s only available trom Engine amp Performance Warehouse ENGINE amp PERFORMANCE WAREHOUSE ALBUQUERQUE 877 7 fay 100 1505 761 0100 DALLAS 800 284 5348 214 637 3301 HOUSTON 800 288 6548 713 862 2929 ANCHORAGE 800 288 5573 907 563 7278 OAKLAND 800 734 1410 510 569 9802 DENVER 800 358 8970 03 572 8844 OKLAHOMA CITY 8 OO 937 3052 405 942 8435 8 3RR 377 6 N2 272 0191 PORTLAND 800 876 5152 503 232 2270 TACOMA 800 876 5152 PHOENIX r 0191 SAN ANTONIO B00 423 2707 210 224 8424 Circle 106 for more information ENGINE BUILDER TECH SOLUTIONS GUIDE February 201
7. ead near zero to slightly positive pressure If a the pan gasket is leaking then perform the repair procedure Note Clean all oil from the interior surfaces of the plenum pan and plenum chamber The proper torque and tightening sequence must be followed when tighten ing both the plenum pan screws and the intake manifold screws Dirt and Debris Accumulating at Rear Main Seal on 1997 2005 Jeep 4 0L This bulletin may be helpful for engine builder customers installers who complain of a small oil leak around the rear main seal Your customer installer may complain of engine oil seepage from the rear main bear ing seal but upon closer inspection may discover the cause of the seepage to be the accumulation of dirt and debris around the outside of the rear main seal This condition may occur more frequently 1f the vehicle is used in off road conditions A spacer plate is used to mate the trans mission bellhousing to the back of the engine The spacer plate has a slot Figure 7 The spacer opening at the top of Jeep 4 0L bellhousings may allow very small debris to enter the bellhousing and accumulate around the outside of the rear main seal CH RY SLE R machined into it at the 12 o clock position A small opening may occur at the spacer slot when the spacer is mounted The nar row spacer opening at the top of the trans mission bellhousing may allow very small debris to enter the bellhousing and accu mulate around the outside of
8. gine This bulletin provides service information for 1998 2002 Chrysler 2 7L engine cylin der head oil gallery cup plugs Each cylinder head on a 2 7L engine has six 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 You must determine which cup plug is leaking before performing this procedure If necessary perform an engine oil leak dye test If it becomes neces sary to service an oil gallery cup plug perform the repair procedure Inspect the cup plug bore in question 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 CUP PLUG BORE CHAMFER ORIGINAL CUP PLUG KEW CUP PLUG 12 mm Figure 5 Drive the new cup plug on 2 7L engine into the bore until the flanged edge of the plug is just inside 1 2 mm the cham Jered edge of the bore and the cylinder 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 vehicle while others require remov ing the affected cylinder head from the engine In either case only replace the L E i i 7 MAHLE Driven by performance ictor R
9. he 4 short bolts are placed in the cor ners of the block marked with an asterisk minum components The MLS gasket can not properly seal if gouging of surfaces metal transfer or composite gasket materi al is left on the head or block surfaces Note This information applies to mod els with a 2 0L SOHC DOHC naturally aspirated or 2 4L engine To properly prepare head block sur faces for MLS gasket installation do the following 1 Following service manual procedures remove the head 2 Remove as much of the loose com posite gasket material with a plastic or wooden scraper Note Prior to additional clean ing inspect the cooling passages of the head Replacement may be necessary if excessive pitting or erosion has taken place that will compromise the sealing surfaces around the cooling passages 3 Cover coolant and oil pas sages to the best of your ability and apply solvent or a commercially available gasket cleaner to the head block surfaces Allow the sol vent to soften the remaining com posite gasket material 4 Using a plastic or wooden scraper scrape the composite gasket residue from the surfaces If necessary apply additional solvent or gasket remover to ease removal 5 If additional cleaning is needed use a drill motor and white 3M Roloc bristle disc p n 07528 to carefully remove the remaining gasket material from the head and block surfaces Note If difficult to remove residue is left
10. inz the Jaraest manufacturer of gaskets in the world today janufactures for virtually every engine manufacturer producing eek worldwide The first manufacturer to ever introduce a _ replacer ent ead ee aa in 131 0 Victor nenz does not t Just pA i 7 a LA Victor Renz and the Vietor Aariz fradamark are property of Dana Limiled ang used under license to MAHLE Clevite inc Circle 109 for more information www enginebuidermag com ENGINEBUILDER 9 on Rt 2 hEN cup plug requiring service 2 Clean the cup plug bore with brake cleaner and compressed air It is not neces sary 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 Figure 5 5 Allow the sealant to cure for at least 20 minutes 6 Assemble any components removed in Step 1 as necessary Spark Knock Oil Consumption on 3 9L 5 2L and 5 9L Engines Caused by Manifold Leak An engine intake manifold plenum pan gasket oil leak may occur on some Dodge 3 9L 5 2L or 5 9L gasoline V6 and V8 engines Two symptoms of this oil leak condi tion may be present Customers may com plain that the vehicle experiences an engine spark knock noise during accelera tion and or a high amount of engine oil consumption The oil leak is inside the engine so no exter
11. l indicating this should be installed TSG 50 Cash Back with the purchase of any 8 cylinder set of SRP or SRP Professional Pistons WWW SPP COM PODALE snus nce win ste protessiona sets 15312 Connector Lane Huntington Beach CA 92649 714 898 9763 srp com Sportsman Racing Products fi i eg L a a e aa or fi rpi r Y c a J lt lt a TT PROCES SIOALAL Now includes SKIRT COATING Circle 113 for more information www enginebuildermag com ENGINE BUILDER 13
12. nal oil leakage will be present The intake manifold plenum pan gasket has been revised to address this condition see Figure 6 If the intake manifold plenum pan gasket is leaking a vacuum source will be created in the engine Any engine blow by and outside fil tered air will be drawn past the leak ing pan gasket and into the intake manifold In most cases an engine at idle will create the highest vacuum and lowest amount of engine blow Figure 6 Oil leaks on some Dodge V6 V8 engines may not leak externally The intake manifold plenum pan gas by ket has been revised to address this condition 1 Remove the positive crankcase ventilation PCV valve at the cylinder head valve cover Clean the PCV valve grommet in the valve cover of any oil residue 2 Remove the breather hose from the air cleaner assembly and seal off the breather hose going to the cylinder head valve cover 3 Attach a gauge that reads both pres sure and vacuum 10 in Hg 4 Start the engine and observe gauge readings If the intake manifold pan gasket ng 5 the industry standard since pper lead composition decades i uccess and notoriety on tracks of all kinds k success provides Gevite the uumate omp ground for Circle 112 for more information 12 ENGINE BUILDER TECH SOLUTIONS GUIDE February 2010 is leaking then a vacuum reading greater than 2 in Hg will be observed If no inter nal leaks are present then the gauge will r
13. rforming these procedures 2 0L DOHC Torque Procedure with MLS Gasket Installation Note The 4 short bolts are placed in the corners of the block marked with an aster isk in Figure 3 which also explains torque sequences A Torque all center bolts to 25 ft lbs 34 Nm torque the 4 corner bolts to 20 ft lbs 27 Nm B Torque all center bolts to 50 ft lbs 68 Nm torque the 4 corner bolts to 35 ft lbs 47 Nm C Re torque all center bolts to 50 ft lbs 68 Nm re torque the 4 corner bolts to 35 ft lbs 47 Nm D Tighten all bolts in the specified sequence Fig 1 an additional 90 1 4 turn Revised 2 4L Cylinder Head Re torque Procedure These procedures apply to vehicles equipped with a 2 4L engine built between February 1 2004 and April 5 2005 1 Using a six inch wobble plus exten sion friction ball and shallow socket follow ing the torque sequence shown in Figure 3 loosen one bolt at a time to 0 torque and then torque that same head bolt to 60 ft Ibs 2 Repeat step 4 for every head bolt one bolt at a time in sequence 3 Verify that each head bolt is at 60 ft lbs before performing next steps 4 After all head bolts have been verified CH RY S LE R to be torqued to 60 ft lbs follow the torque sequence and turn the head bolts an additional 90 1 4 turn 5 Following the appropriate proce dures install the cylinder head cover Outer Exhaust Manifold Studs Breaking on 1991 1999 Jeep 2 5L
14. the rear main engine seal If debris accumulation becomes significant damage to the rear main seal may result Repair Procedure 1 Locate the narrow opening created by the spacer plate see Figure 7 The spacer opening can be seen when looking toward the rear of the engine and top of the transmission 2 Thoroughly clean the immediate area around the spacer opening with throttle body cleaner p n 04897156AA Allow cleaner to dry see Figure 8 3 Apply a sufficient amount of RTV over the spacer opening Verify that the spacer opening 1s completely sealed off by the RTV Engine Whine at Idle Reported on Some Chrysler 6 1L Hemi Engines This bulletin applies to 2005 2006 Chrysler models equipped with a 6 1L engine with an engine serial number of TNXE6026620001 or less The engine serial number can be found on a label located on the upper side of the left or right engine front cover Some customers may notice a whine sound at idle after the vehicle has been driven engine hot in warm ambient tem peratures over 50 F 10 C This sound can be caused by the piston oil cooler jets fluttering during hot oil idle conditions Installers must carefully diagnose this whine sound since it can be confused with other sounds that come from the engine compartment 1 Run the engine until the oil is hot Figure 8 Thoroughly clean the immediate area around 4 0L spacer opening with throt tle body cleaner and allow to dry over 2
Download Pdf Manuals
Related Search