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If you are anywhere near 100K on your 2.7, its time to start thinking about replacing a few components. The timing chain, guides, tensioner, waterpump, oil pump, oil pickup tube, and valve stem seals tend to go on alot on these cars. Using the manuals located at http://dvms.dvusd.org/02lhe/ i created a step by step guide on exactly how to do this and what special tools will be needed. The manual gets pretty repetitive, so here are the condensed steps if you were to change out all of the above mentioned:
Special tools needed:
Special Tool 8191- Hold the crankshaft damper so that center bolt can be removed and tightend
Special Tools 8194 and 1023 Three Jaw Puller – removes dampener
Special Tools 8179 Screw, Nut and Thrust Bearing from 6792, and 6792-1 used to install the vibration dampener
Special Tools 5048-1, 5048-6, and 8539 used to remove crankshaft sprocket
Special Tools 8215 and 8216 Adaptor used to depress valve spring to release tension on rocker arm
Special Tool MD 998772A with adapter 6779 used to compress valve spring so that locks, retainer and spring can be removed
Special Tool 8186 – used for depressing the check ball end of the tensioner to purge oil from the tensioner
Mopart Engine RTV GEN II
Special Tool 6780-2 sleeve and 6780-2 – used to install crankshaft oil
Special Tool 8195- filling aid funnel to pressure bottle filler neck
(1) Perform fuel system pressure release procedure
before attempting any repairs.
(2) Disconnect negative cable from remote jumper
terminal.
(3) Remove air cleaner housing and inlet hose.
(4) Disconnect Inlet Air Temperature (IAT) Sensor
connector. Remove air inlet resonator and inlet tube.
(5) Remove throttle cable and speed control cable
from throttle arm and bracket by doing the following:
Working from the engine compartment, hold
the throttle body throttle lever in the wide open position.
Pull the cable forward and slide it out of the
throttle body cam.
(6) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft (Fig. 1).
(7) Remove retainer clip from throttle cable and
grommet at dash panel (Fig. 2).
(8) From the engine compartment, pull the throttle
cable out of the dash panel grommet. The grommet
should remain in the dash panel.
(9) Remove the throttle cable from throttle bracket
by carefully compressing both retaining ears simultaneously.
Then gently pull the throttle cable from
throttle bracket.
(10) Remove throttle cable bracket.
(11) Disconnect electrical connectors from the following
components:
² Manifold Absolute Pressure (MAP) Sensor
² Throttle Position Sensor (TPS) Sensor
² Idle Air Control (IAC) Motor
(12) Disconnect Vapor Purge hose, Brake Booster
hose, Speed Control Servo, Positive Crankcase Ventilation
(PCV) hose (Fig. 105).
(13) Loosen upper fastener at throttle body support
bracket.
(14) Remove manifold attaching bolts (Fig. 107).
(15) Remove upper manifold (Fig. 106).
(16) Remove cylinder head covers. (Refer to 9 -
(17) Drain cooling system
When servicing the cooling system, it is essential
that coolant does not drip on the drive belts or pulleys.
If neccessary, shield the belts with shop towels
before working on the cooling system. If coolant contacts
the belts or pulleys, flush both with clean
water.
WARNING: DO NOT REMOVE HOSE CLAMPS OR
HOSES, CYLINDER BLOCK DRAIN PLUGS, COOLANT
BOTTLE CAP, OR OPEN THE RADIATOR
DRAINCOCK, WHEN THE SYSTEM IS HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM THE COOLANT CAN OCCUR.
The radiator draincock that is located at the lower
right side of radiator (Fig. 4). The draincock stem is
closed in the horizontal position, pointing to 3:00
o’clock. Draining takes place through the cooling
module’s lower right side insulator. Do Not Use pliers
to open draincock.
CAUTION: Do not pull outward on the draincock
flange while opening. Damage to the draincock
body and O-ring seal may occur
(18) To open the draincock to the minimum drain
position, turn the draincock stem countercolockwise
to the 12:00 o’clock position. For the maximum drain
position, turn draincock stem counterclockwise 180
degrees to the 9:00 o’clock position.
(19) Remove coolant pressure bottle cap and open the bleed valve.
(20) Remove the cylinder block drain plug(s) located
below each exhaust manifold.
Most service drains are about 80 percent of capacity
because not all coolant is drained from system.
For capacity specifications, (Refer to LUBRICATION
& MAINTENANCE - SPECIFICATIONS - FLUID
CAPACITIES)
CAUTION: The cooling system normally operates at
97-124 kPa (14-18 psi) pressure. Exceeding this
pressure may damage the radiator or hoses.
DRIVE BELTS - 2.7L
REMOVAL
GENERATOR/POWER STEERING BELT
(21) Loosen tensioner pulley locking nut (Fig. 1).
(22) Loosen belt adjusting bolt (Fig. 1).
(23) Remove generator/power steering belt.
AIR CONDITIONING BELT
NOTE: The A/C drive belt self tensioner is NOT a
dynamic tensioner. After adjustment the tensioner
bracket bolts are tightened. The torsion spring is no
longer responsible for tensioning the A/C belt. The
torsion spring is only used for initial belt tensioning.
(24) Remove generator/power steering belt to gain
access to A/C belt. Refer to GENERATOR/POWER
STEERING BELT for procedure.
(25) Loosen BUT DO NOT REMOVE tensioner
locking bolt and pivot bolt (Fig. 2).
(26) Insert 1/2” drive breaker bar into square opening
on belt tensioner. Rotate tensioner counterclockwise
until belt can be removed from pulleys (Fig. 2).
(27) Slowly rotate tensioner clockwise to relieve
spring load.
(28) Remove the vibration dampener by removing the upper radiator cromssmember.
(29) Mark bolt locations on the upper radiator closure
panel.
(30) Remove bolts attaching windshield washer bottle
and speed control servo, if equipped (Fig. 4).
(31) Remove headlamp jackscrews both sides.
(32) Remove fasteners attaching upper bumper fascia.
(33) Remove bolts attaching the forward edge of
upper radiator closure panel.
(34) Remove bolts attaching upper radiator closure
panel.
(35) Disconnect hood latch cable from hood latch.
(36) Remove upper radiator closure panel from vehicle.
(37) Disconnect radiator fan motor electrical connector.
(38) Partially drain cooling system below the level
of the upper radiator hose.
(39) Disconnect upper radiator hose from radiator.
(40) Remove radiator fan attaching fasteners and
upper clip (Fig. 24).
(41) Remove radiator fan by lifting upward to clear
(42) Remove damper center bolt while holding the
damper with Special Tool 8191 (Fig. 76).
CAUTION: Before removing damper, verify that A/C
belt tensioner is not contacting the damper, as
damage could occur to tensioner, timing chain
cover, and/or damper.
(43) Remove damper by using Special Tools 8194
and 1023 Three Jaw Puller (Fig. 77).
(44) Remove lower intake manifold by the following:
(45) Disconnect electrical connectors from the fuel
injectors.
(46) Remove fuel supply hose from fuel rail.
(47) Remove screw attaching fuel rail support
bracket to the throttle body support bracket.
(48) Remove bolts attaching fuel rail.
(49) Remove fuel rail and injectors as an assembly.
(50) Remove manifold attaching bolts (Fig. 108).
(51) Remove lower manifold.
(52) Inspect manifold
(53) Remove cylinder head cover and timing chain
cover by the following:
(56) Remove power steering pump from mounting
bracket.
(57) Remove accessory drive belt tensioner pulley
and bracket.
(58) Remove timing chain cover attaching bolts and
remove cover.
(59) Now ready to remove the timing chain and sprokets
CAUTION: When aligning timing marks, always
rotate engine by turning the crankshaft. Failure to
do so will result in valve and/or piston damage.
(60) Align crankshaft sprocket timing mark to mark
on oil pump housing (Fig. 116). The mark on oil
pump housing is 60° ATDC of #1 cylinder.
CAUTION: When the timing chain is removed and
the cylinder heads are still 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.
(61) Remove primary timing chain tensioner from
right cylinder head (Fig. 117).
(62) Remove camshaft position sensor from left cylinder
head (Fig. 118).
(63) Remove chain guide access plug from left cylinder
head (Fig. 118).
NOTE: When camshaft sprocket bolts are removed,
the camshafts will rotate in a clockwise direction.
(64) Starting with the right camshaft sprocket,
remove the sprocket attaching bolts. Remove camshaft
damper (if equipped) and sprocket (Fig. 118).
(65) Remove left side camshaft sprocket attaching
bolts and remove sprocket (Fig. 118).
(66) Remove lower chain guide and tensioner arm
(Fig. 118).
(67) Remove the primary timing chain.
(68) For removal of crankshaft sprocket,
CAUTION: Use care not to turn crankshaft while
removing crankshaft sprocket, as damage to valves
and or pistons could occur.
(69) Remove crankshaft sprocket by first installing
the crankshaft damper bolt. Apply grease or equivalent
to damper bolt head and position Special Tools
5048-1, 5048-6, and 8539 on sprocket and crankshaft
nose (Fig. 119). Remove sprocket using care not to
rotate the crankshaft.
WATER PUMP - 2.7
REMOVAL
The water pump on all models can be replaced
without discharging the air conditioning system.
NOTE: It is normal for the water pump to weep a
small amount of coolant from the weep hole (black
stain at weep passage). Do not replace the water
pump if this condition exists. Replace the water
pump if a heavy deposit or a steady flow of engine
coolant is evident on side of the cylinder block
from the weep hole passage (shaft seal failure). Be
sure to perform a thorough analysis before replacing
water pump.
(70) Remove the timing chain guides-
(71) Remove bolts attaching water pump to block
(Fig. 28).
(72) Remove water pump and gasket.
WATER PUMP INSTALLATION
(73) Clean all sealing surfaces.
(74) Install water pump and gasket. Tighten mounting
bolts to 12 N•m (105 in. lbs.).
REMOVE OIL PUMP
The oil pump pressure relief valve can be serviced
by removing the oil pan.
(75) Remove oil pan by the following method.
(76) Remove dipstick and tube.
(77) Raise vehicle on hoist.
(78) Drain engine oil and remove oil filter.
(79) Disconnect suspension stabilizer bar and reposition
for oil pan clearance by doing the following:
(80) Remove the 4 strut assembly upper mount to
strut tower mounting nut and washer assemblies
securing the right front strut in place (Fig. 37).
(81) Raise vehicle on jack stands or centered on a
frame contact hoist. See Hoisting in Lubrication and
Maintenance.
(82) Remove right front wheel and tire assembly
from the vehicle.
(83) Remove structural collar from oil pan to transmission
housing (Fig. 91).
(84) Remove lower bolt attaching the A/C compressor
to oil pan.
(85) Disconnect engine oil cooler line from pan (if
equipped).
CAUTION: Assure removal of the two bolts attaching
the timing cover to the oil pan, as damage to
the timing cover and/or oil pan may occur.
(86) Remove oil pan attaching fasteners. Remove oil
pan and gasket (Fig. 92).
(87) Remove oil pick-up tube and O-ring (Fig. 95).
(88) Ensure that crankshaft position is at 60° ATDC
of No.1 cylinder, or crankshaft sprocket mark aligns
with mark on oil pump (Fig. 94). This position will
properly locate oil pump upon installation.
(89) Remove oil pump attaching bolts (Fig. 95).
(90) Remove oil pump.
OIL PUMP and PICKUP TUBE INSTALLATION
OIL PUMP INSTALLATION
CAUTION: Crankshaft position must be at 60° ATDC
of No.1 cylinder before installing oil pump (Fig. 94).
This position will properly locate oil pump. If not
properly located, severe damage to oil pump can
occur.
(91) Prime oil pump before installation by filling
rotor cavity with engine oil.
(92) If crankshaft has been rotated, it must be repositioned
to 60° ATDC of No.1 cylinder prior to oil
pump installation (Fig. 94).
(93) Install oil pump carefully over crankshaft and
into position.
(94) Install oil pump attaching bolts. Tighten bolts
to 28 N•m (250 in. lbs.) (Fig. 95).
(95) Install oil pick-up tube with new O-ring. Lubricate
O-ring before installation. Tighten attaching
bolts to 28 N•m (250 in. lbs.) (Fig. 95).
(96) Install oil pan by the following
OIL PAN INSTALLATION
(97) Clean oil pan and sealing surfaces. Inspect oil
pan and timing chain cover gaskets. Replace as necessary.
(98) Apply an 1/8 inch bead of Mopart Engine RTV
GEN II to the front T-joints (oil pan gasket to timing
cover gasket interface) and the rear T-joints (oil pan
interface) (Fig. 92).
(99) Install oil pan gasket to block.
NOTE: To prevent oil leaks at oil pan to timing
chain cover, the following tightening sequence procedure
must be performed.
(100) Install oil pan and fasteners (Fig. 92) using the
following tightening sequence:
(a) Install oil pan bolts and nuts finger tight
only—just tight enough to compress the gasket’s
rubber seal.
(b) Install timing chain cover to pan bolts and
tighten to 12 N•m (105 in. lbs.).
(c) Tighten oil pan bolts to 28 N•m (250 in. lbs.).
(d) Tighten oil pan nuts to 12 N•m (105 in. lbs.).
(5) Install lower bolt attaching the A/C compressor
to oil pan. Tighten bolt to 28 N•m (21 ft. lbs.).
(101) Connect engine oil cooler line to oil pan (if
equipped).
CAUTION: The collar must be tighten using the following
procedure, as damage to the collar or oil
pan may occur.
(102) Install structural collar (Fig. 91) using the following
tightening sequence:
(a) Install the vertical collar to oil pan bolts.
Torque bolts initially to 1.1 N•m (10 in. lbs.).
(b) Install the horizontal collar to transmission
bolts and torque to 55 N•m (40 ft. lbs.).
(c) Starting with the center vertical bolts and
working outward, final torque bolts to 55 N•m (40
ft. lbs.).
(103) Install oil filter and drain plug.
(104) Connect suspension stabilizer bar by the following:
(105) Install stabilizer bar by reversing the manner
in which it was removed (Fig. 47). Rotate the bar the
opposite direction used when removed and move it
into mounting position.
CAUTION: Be careful not to pull knuckle outward,
thus stretching halfshaft and possibly separating
inner C/V joint. See Driveshafts. Keep knuckle in
upright position.
(106) Lower the jack supporting the engine, guiding
the motor mount studs into place in the cradle
assembly (Fig. 46).
(107) Install the 4 engine motor mount to cradle
assembly attaching nuts (Fig. 44). Tighten the 4 nuts
to a torque of 61 N•m (45 ft. lbs).
pan and the transaxle. The structural collar should
be installed using the following sequence:
² Position collar onto engine oil pan and transaxle
(Fig. 43).
² Install the 2 center collar bolts to oil pan bolts.
Tighten bolts initially to 3 N•m (30 in. lbs).
² Install collar to transmission bolts and tighten
to 61 N•m (45 ft. lbs).
² Install the remaining collar to engine oil pan
bolts. starting with the center bolts and working outwards,
tighten collar to oil pan bolts to 61 N•m (45 ft.
lbs).
(108) Install stabilizer bar isolator bushings onto stabilizer
bar with slits facing forward and flat side facing
downward. The stabilizer bar to cradle
assembly bushings must be positioned on the
stabilizer bar so the slit in the bushing is positioned
toward front of vehicle (Fig. 48).
(109) Install the isolator bushing retainers onto the
stabilizer bar isolator bushings (Fig. 45).
CAUTION: When stabilizer bar is installed, position
stabilizer bar so lower part of stabilizer bar is centered
in the middle of the cradle assembly. Failure
to do this may cause stabilizer bar to come in contact
with other suspension components.
(110) Align the stabilizer bar bushing retainers with
the mounting holes in the cradle assembly. Install
and tighten the 4 stabilizer bar bushing retainer to
cradle assembly attaching bolts to 61 N•m (45 ft.
lbs.). (Fig. 45).
(111) Install left side stabilizer bar attaching link to
left end of stabilizer bar (Fig. 39). Install attaching
nut and tighten to 95 N•m (70 ft. lbs.).
(112) Install right front strut assembly into shock
tower. Install the 4 strut assembly upper mount to
shock tower attaching nuts (Fig. 37). Tighten the 4
strut mount to strut tower attaching nuts to a torque
of 45 N•m (33 ft. lbs.) torque.
(113) Position steering knuckle into strut assembly.
CAUTION: The strut assembly to steering knuckle
bolts are serrated were they go through strut
assembly and steering knuckle. When installing
bolts, turn nuts onto bolts DO NOT TURN BOLTS IN
STEERING KNUCKLE. If bolts are turned damage to
steering knuckle will result.
(114) Install the strut assembly to steering knuckle
attaching bolts (Fig. 42). Install nuts on attaching
bolts. Tighten the strut assembly to steering knuckle
attaching bolt nuts to a torque of 203 N•m (150 ft.
lbs.).
(115) If the vehicle is equipped with antilock
brakes. Install the front speed sensor cable routing
bracket onto the front strut assembly (Fig. 41).
(116) Install outer tie rod on strut assembly. Install
tie rod attaching nut (Fig. 38). Tighten the tie rod
attaching nut to a torque of 37 N•m (27 ft. lbs.).
(117) Install stabilizer bar link on strut (Fig. 38).
Tighten the stabilizer link attaching nut to a torque
of 95 N•m (70 ft. lbs.).
(118) Install the right front wheel and tire assembly.
(119) Lower vehicle and install oil dipstick and
tube.
Special tools needed:
Special Tool 8191- Hold the crankshaft damper so that center bolt can be removed and tightend
Special Tools 8194 and 1023 Three Jaw Puller – removes dampener
Special Tools 8179 Screw, Nut and Thrust Bearing from 6792, and 6792-1 used to install the vibration dampener
Special Tools 5048-1, 5048-6, and 8539 used to remove crankshaft sprocket
Special Tools 8215 and 8216 Adaptor used to depress valve spring to release tension on rocker arm
Special Tool MD 998772A with adapter 6779 used to compress valve spring so that locks, retainer and spring can be removed
Special Tool 8186 – used for depressing the check ball end of the tensioner to purge oil from the tensioner
Mopart Engine RTV GEN II
Special Tool 6780-2 sleeve and 6780-2 – used to install crankshaft oil
Special Tool 8195- filling aid funnel to pressure bottle filler neck
(1) Perform fuel system pressure release procedure
before attempting any repairs.
(2) Disconnect negative cable from remote jumper
terminal.
(3) Remove air cleaner housing and inlet hose.
(4) Disconnect Inlet Air Temperature (IAT) Sensor
connector. Remove air inlet resonator and inlet tube.
(5) Remove throttle cable and speed control cable
from throttle arm and bracket by doing the following:
Working from the engine compartment, hold
the throttle body throttle lever in the wide open position.
Pull the cable forward and slide it out of the
throttle body cam.
(6) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft (Fig. 1).
(7) Remove retainer clip from throttle cable and
grommet at dash panel (Fig. 2).
(8) From the engine compartment, pull the throttle
cable out of the dash panel grommet. The grommet
should remain in the dash panel.
(9) Remove the throttle cable from throttle bracket
by carefully compressing both retaining ears simultaneously.
Then gently pull the throttle cable from
throttle bracket.
(10) Remove throttle cable bracket.
(11) Disconnect electrical connectors from the following
components:
² Manifold Absolute Pressure (MAP) Sensor
² Throttle Position Sensor (TPS) Sensor
² Idle Air Control (IAC) Motor
(12) Disconnect Vapor Purge hose, Brake Booster
hose, Speed Control Servo, Positive Crankcase Ventilation
(PCV) hose (Fig. 105).
(13) Loosen upper fastener at throttle body support
bracket.
(14) Remove manifold attaching bolts (Fig. 107).
(15) Remove upper manifold (Fig. 106).
(16) Remove cylinder head covers. (Refer to 9 -
(17) Drain cooling system
When servicing the cooling system, it is essential
that coolant does not drip on the drive belts or pulleys.
If neccessary, shield the belts with shop towels
before working on the cooling system. If coolant contacts
the belts or pulleys, flush both with clean
water.
WARNING: DO NOT REMOVE HOSE CLAMPS OR
HOSES, CYLINDER BLOCK DRAIN PLUGS, COOLANT
BOTTLE CAP, OR OPEN THE RADIATOR
DRAINCOCK, WHEN THE SYSTEM IS HOT AND
UNDER PRESSURE BECAUSE SERIOUS BURNS
FROM THE COOLANT CAN OCCUR.
The radiator draincock that is located at the lower
right side of radiator (Fig. 4). The draincock stem is
closed in the horizontal position, pointing to 3:00
o’clock. Draining takes place through the cooling
module’s lower right side insulator. Do Not Use pliers
to open draincock.
CAUTION: Do not pull outward on the draincock
flange while opening. Damage to the draincock
body and O-ring seal may occur
(18) To open the draincock to the minimum drain
position, turn the draincock stem countercolockwise
to the 12:00 o’clock position. For the maximum drain
position, turn draincock stem counterclockwise 180
degrees to the 9:00 o’clock position.
(19) Remove coolant pressure bottle cap and open the bleed valve.
(20) Remove the cylinder block drain plug(s) located
below each exhaust manifold.
Most service drains are about 80 percent of capacity
because not all coolant is drained from system.
For capacity specifications, (Refer to LUBRICATION
& MAINTENANCE - SPECIFICATIONS - FLUID
CAPACITIES)
CAUTION: The cooling system normally operates at
97-124 kPa (14-18 psi) pressure. Exceeding this
pressure may damage the radiator or hoses.
DRIVE BELTS - 2.7L
REMOVAL
GENERATOR/POWER STEERING BELT
(21) Loosen tensioner pulley locking nut (Fig. 1).
(22) Loosen belt adjusting bolt (Fig. 1).
(23) Remove generator/power steering belt.
AIR CONDITIONING BELT
NOTE: The A/C drive belt self tensioner is NOT a
dynamic tensioner. After adjustment the tensioner
bracket bolts are tightened. The torsion spring is no
longer responsible for tensioning the A/C belt. The
torsion spring is only used for initial belt tensioning.
(24) Remove generator/power steering belt to gain
access to A/C belt. Refer to GENERATOR/POWER
STEERING BELT for procedure.
(25) Loosen BUT DO NOT REMOVE tensioner
locking bolt and pivot bolt (Fig. 2).
(26) Insert 1/2” drive breaker bar into square opening
on belt tensioner. Rotate tensioner counterclockwise
until belt can be removed from pulleys (Fig. 2).
(27) Slowly rotate tensioner clockwise to relieve
spring load.
(28) Remove the vibration dampener by removing the upper radiator cromssmember.
(29) Mark bolt locations on the upper radiator closure
panel.
(30) Remove bolts attaching windshield washer bottle
and speed control servo, if equipped (Fig. 4).
(31) Remove headlamp jackscrews both sides.
(32) Remove fasteners attaching upper bumper fascia.
(33) Remove bolts attaching the forward edge of
upper radiator closure panel.
(34) Remove bolts attaching upper radiator closure
panel.
(35) Disconnect hood latch cable from hood latch.
(36) Remove upper radiator closure panel from vehicle.
(37) Disconnect radiator fan motor electrical connector.
(38) Partially drain cooling system below the level
of the upper radiator hose.
(39) Disconnect upper radiator hose from radiator.
(40) Remove radiator fan attaching fasteners and
upper clip (Fig. 24).
(41) Remove radiator fan by lifting upward to clear
(42) Remove damper center bolt while holding the
damper with Special Tool 8191 (Fig. 76).
CAUTION: Before removing damper, verify that A/C
belt tensioner is not contacting the damper, as
damage could occur to tensioner, timing chain
cover, and/or damper.
(43) Remove damper by using Special Tools 8194
and 1023 Three Jaw Puller (Fig. 77).
(44) Remove lower intake manifold by the following:
(45) Disconnect electrical connectors from the fuel
injectors.
(46) Remove fuel supply hose from fuel rail.
(47) Remove screw attaching fuel rail support
bracket to the throttle body support bracket.
(48) Remove bolts attaching fuel rail.
(49) Remove fuel rail and injectors as an assembly.
(50) Remove manifold attaching bolts (Fig. 108).
(51) Remove lower manifold.
(52) Inspect manifold
(53) Remove cylinder head cover and timing chain
cover by the following:
(56) Remove power steering pump from mounting
bracket.
(57) Remove accessory drive belt tensioner pulley
and bracket.
(58) Remove timing chain cover attaching bolts and
remove cover.
(59) Now ready to remove the timing chain and sprokets
CAUTION: When aligning timing marks, always
rotate engine by turning the crankshaft. Failure to
do so will result in valve and/or piston damage.
(60) Align crankshaft sprocket timing mark to mark
on oil pump housing (Fig. 116). The mark on oil
pump housing is 60° ATDC of #1 cylinder.
CAUTION: When the timing chain is removed and
the cylinder heads are still 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.
(61) Remove primary timing chain tensioner from
right cylinder head (Fig. 117).
(62) Remove camshaft position sensor from left cylinder
head (Fig. 118).
(63) Remove chain guide access plug from left cylinder
head (Fig. 118).
NOTE: When camshaft sprocket bolts are removed,
the camshafts will rotate in a clockwise direction.
(64) Starting with the right camshaft sprocket,
remove the sprocket attaching bolts. Remove camshaft
damper (if equipped) and sprocket (Fig. 118).
(65) Remove left side camshaft sprocket attaching
bolts and remove sprocket (Fig. 118).
(66) Remove lower chain guide and tensioner arm
(Fig. 118).
(67) Remove the primary timing chain.
(68) For removal of crankshaft sprocket,
CAUTION: Use care not to turn crankshaft while
removing crankshaft sprocket, as damage to valves
and or pistons could occur.
(69) Remove crankshaft sprocket by first installing
the crankshaft damper bolt. Apply grease or equivalent
to damper bolt head and position Special Tools
5048-1, 5048-6, and 8539 on sprocket and crankshaft
nose (Fig. 119). Remove sprocket using care not to
rotate the crankshaft.
WATER PUMP - 2.7
REMOVAL
The water pump on all models can be replaced
without discharging the air conditioning system.
NOTE: It is normal for the water pump to weep a
small amount of coolant from the weep hole (black
stain at weep passage). Do not replace the water
pump if this condition exists. Replace the water
pump if a heavy deposit or a steady flow of engine
coolant is evident on side of the cylinder block
from the weep hole passage (shaft seal failure). Be
sure to perform a thorough analysis before replacing
water pump.
(70) Remove the timing chain guides-
(71) Remove bolts attaching water pump to block
(Fig. 28).
(72) Remove water pump and gasket.
WATER PUMP INSTALLATION
(73) Clean all sealing surfaces.
(74) Install water pump and gasket. Tighten mounting
bolts to 12 N•m (105 in. lbs.).
REMOVE OIL PUMP
The oil pump pressure relief valve can be serviced
by removing the oil pan.
(75) Remove oil pan by the following method.
(76) Remove dipstick and tube.
(77) Raise vehicle on hoist.
(78) Drain engine oil and remove oil filter.
(79) Disconnect suspension stabilizer bar and reposition
for oil pan clearance by doing the following:
(80) Remove the 4 strut assembly upper mount to
strut tower mounting nut and washer assemblies
securing the right front strut in place (Fig. 37).
(81) Raise vehicle on jack stands or centered on a
frame contact hoist. See Hoisting in Lubrication and
Maintenance.
(82) Remove right front wheel and tire assembly
from the vehicle.
(83) Remove structural collar from oil pan to transmission
housing (Fig. 91).
(84) Remove lower bolt attaching the A/C compressor
to oil pan.
(85) Disconnect engine oil cooler line from pan (if
equipped).
CAUTION: Assure removal of the two bolts attaching
the timing cover to the oil pan, as damage to
the timing cover and/or oil pan may occur.
(86) Remove oil pan attaching fasteners. Remove oil
pan and gasket (Fig. 92).
(87) Remove oil pick-up tube and O-ring (Fig. 95).
(88) Ensure that crankshaft position is at 60° ATDC
of No.1 cylinder, or crankshaft sprocket mark aligns
with mark on oil pump (Fig. 94). This position will
properly locate oil pump upon installation.
(89) Remove oil pump attaching bolts (Fig. 95).
(90) Remove oil pump.
OIL PUMP and PICKUP TUBE INSTALLATION
OIL PUMP INSTALLATION
CAUTION: Crankshaft position must be at 60° ATDC
of No.1 cylinder before installing oil pump (Fig. 94).
This position will properly locate oil pump. If not
properly located, severe damage to oil pump can
occur.
(91) Prime oil pump before installation by filling
rotor cavity with engine oil.
(92) If crankshaft has been rotated, it must be repositioned
to 60° ATDC of No.1 cylinder prior to oil
pump installation (Fig. 94).
(93) Install oil pump carefully over crankshaft and
into position.
(94) Install oil pump attaching bolts. Tighten bolts
to 28 N•m (250 in. lbs.) (Fig. 95).
(95) Install oil pick-up tube with new O-ring. Lubricate
O-ring before installation. Tighten attaching
bolts to 28 N•m (250 in. lbs.) (Fig. 95).
(96) Install oil pan by the following
OIL PAN INSTALLATION
(97) Clean oil pan and sealing surfaces. Inspect oil
pan and timing chain cover gaskets. Replace as necessary.
(98) Apply an 1/8 inch bead of Mopart Engine RTV
GEN II to the front T-joints (oil pan gasket to timing
cover gasket interface) and the rear T-joints (oil pan
interface) (Fig. 92).
(99) Install oil pan gasket to block.
NOTE: To prevent oil leaks at oil pan to timing
chain cover, the following tightening sequence procedure
must be performed.
(100) Install oil pan and fasteners (Fig. 92) using the
following tightening sequence:
(a) Install oil pan bolts and nuts finger tight
only—just tight enough to compress the gasket’s
rubber seal.
(b) Install timing chain cover to pan bolts and
tighten to 12 N•m (105 in. lbs.).
(c) Tighten oil pan bolts to 28 N•m (250 in. lbs.).
(d) Tighten oil pan nuts to 12 N•m (105 in. lbs.).
(5) Install lower bolt attaching the A/C compressor
to oil pan. Tighten bolt to 28 N•m (21 ft. lbs.).
(101) Connect engine oil cooler line to oil pan (if
equipped).
CAUTION: The collar must be tighten using the following
procedure, as damage to the collar or oil
pan may occur.
(102) Install structural collar (Fig. 91) using the following
tightening sequence:
(a) Install the vertical collar to oil pan bolts.
Torque bolts initially to 1.1 N•m (10 in. lbs.).
(b) Install the horizontal collar to transmission
bolts and torque to 55 N•m (40 ft. lbs.).
(c) Starting with the center vertical bolts and
working outward, final torque bolts to 55 N•m (40
ft. lbs.).
(103) Install oil filter and drain plug.
(104) Connect suspension stabilizer bar by the following:
(105) Install stabilizer bar by reversing the manner
in which it was removed (Fig. 47). Rotate the bar the
opposite direction used when removed and move it
into mounting position.
CAUTION: Be careful not to pull knuckle outward,
thus stretching halfshaft and possibly separating
inner C/V joint. See Driveshafts. Keep knuckle in
upright position.
(106) Lower the jack supporting the engine, guiding
the motor mount studs into place in the cradle
assembly (Fig. 46).
(107) Install the 4 engine motor mount to cradle
assembly attaching nuts (Fig. 44). Tighten the 4 nuts
to a torque of 61 N•m (45 ft. lbs).
pan and the transaxle. The structural collar should
be installed using the following sequence:
² Position collar onto engine oil pan and transaxle
(Fig. 43).
² Install the 2 center collar bolts to oil pan bolts.
Tighten bolts initially to 3 N•m (30 in. lbs).
² Install collar to transmission bolts and tighten
to 61 N•m (45 ft. lbs).
² Install the remaining collar to engine oil pan
bolts. starting with the center bolts and working outwards,
tighten collar to oil pan bolts to 61 N•m (45 ft.
lbs).
(108) Install stabilizer bar isolator bushings onto stabilizer
bar with slits facing forward and flat side facing
downward. The stabilizer bar to cradle
assembly bushings must be positioned on the
stabilizer bar so the slit in the bushing is positioned
toward front of vehicle (Fig. 48).
(109) Install the isolator bushing retainers onto the
stabilizer bar isolator bushings (Fig. 45).
CAUTION: When stabilizer bar is installed, position
stabilizer bar so lower part of stabilizer bar is centered
in the middle of the cradle assembly. Failure
to do this may cause stabilizer bar to come in contact
with other suspension components.
(110) Align the stabilizer bar bushing retainers with
the mounting holes in the cradle assembly. Install
and tighten the 4 stabilizer bar bushing retainer to
cradle assembly attaching bolts to 61 N•m (45 ft.
lbs.). (Fig. 45).
(111) Install left side stabilizer bar attaching link to
left end of stabilizer bar (Fig. 39). Install attaching
nut and tighten to 95 N•m (70 ft. lbs.).
(112) Install right front strut assembly into shock
tower. Install the 4 strut assembly upper mount to
shock tower attaching nuts (Fig. 37). Tighten the 4
strut mount to strut tower attaching nuts to a torque
of 45 N•m (33 ft. lbs.) torque.
(113) Position steering knuckle into strut assembly.
CAUTION: The strut assembly to steering knuckle
bolts are serrated were they go through strut
assembly and steering knuckle. When installing
bolts, turn nuts onto bolts DO NOT TURN BOLTS IN
STEERING KNUCKLE. If bolts are turned damage to
steering knuckle will result.
(114) Install the strut assembly to steering knuckle
attaching bolts (Fig. 42). Install nuts on attaching
bolts. Tighten the strut assembly to steering knuckle
attaching bolt nuts to a torque of 203 N•m (150 ft.
lbs.).
(115) If the vehicle is equipped with antilock
brakes. Install the front speed sensor cable routing
bracket onto the front strut assembly (Fig. 41).
(116) Install outer tie rod on strut assembly. Install
tie rod attaching nut (Fig. 38). Tighten the tie rod
attaching nut to a torque of 37 N•m (27 ft. lbs.).
(117) Install stabilizer bar link on strut (Fig. 38).
Tighten the stabilizer link attaching nut to a torque
of 95 N•m (70 ft. lbs.).
(118) Install the right front wheel and tire assembly.
(119) Lower vehicle and install oil dipstick and
tube.
