Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual - part 496

(17) Connect positive cable to battery and PDC.
(18) Raise vehicle on hoist.
(19) Install torque converter bolts.
(20) Install structural collar and torque reaction

bracket (Refer to 9 - ENGINE/ENGINE BLOCK/
STRUCTURAL COVER - INSTALLATION).

(21) Install rear mount bracket to transmission.
(22) Install front and rear engine mount through

bolts. Torque fasteners to 61 N·m (45 ft. lbs.).

(23) Connect exhaust pipe to exhaust manifold.

Torque fasteners to 28 N·m (250 in. lbs.).

(24) Connect A/C compressor electrical connectors.
(25) Connect heater return hose to pipe connection

at right front frame rail area.

(26) Install power steering pump to bracket.
(27) Install accessory drive belts (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

-

INSTALLATION).

(28) Install both axle shafts (Refer to 3 - DIFFER-

ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION).

(29) Install new oil filter.
(30) Install left and right splash shields.
(31) Install both front wheels.
(32) Lower vehicle.
(33) Connect engine electrical harness to PCM and

bulkhead connectors.

(34) Connect transmission shift cable.
(35) Connect

transmission

electrical

connectors

(C104 & C105) (Refer to 8 - ELECTRICAL/CONNEC-
TOR/GROUND LOCATIONS - DESCRIPTION).

(36) Install cooling module assembly (radiator, fan

module, and condenser). Connect A/C lines to con-
denser.

(37) Connect transmission oil cooler lines using

service splice kit. Refer to instructions provided with
kit.

(38) Connect upper and lower radiator hoses.
(39) Install upper radiator crossmember.
(40) Install throttle body air inlet hose and air

cleaner housing assembly.

(41) Fill engine crankcase with proper oil to cor-

rect level.

(42) Evacuate and recharge A/C system (Refer to

24 - HEATING & AIR CONDITIONING - STAN-
DARD PROCEDURE).

(43) Fill cooling system (Refer to 7 - COOLING/

ENGINE - STANDARD PROCEDURE).

(44) Connect negative battery cable.
(45) Start engine and run until normal operating

temperature is reached.

SPECIFICATIONS

2.4L ENGINE

GENERAL SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Metric

Standard

Type

In-Line OHV, DOHC

Number of
Cylinders

4

Firing Order

1-3-4-2

Compression
Ratio

9.5:1

Max. Variation
Between
Cylinders

25%

Displacement

2.4 Liters

148 cu. in.

Bore

87.5 mm

3.445 in.

Stroke

101.0 mm

3.976 in.

Compression
Pressure

1172-1551 kPa

170-225 psi

CYLINDER BLOCK

DESCRIPTION

SPECIFICATION

Metric

Standard

Cylinder Bore
Diameter

87.4924-

87.5076 mm

3.4446-3.4452

in.

Out-of-Round
(Max.)

0.051 mm

0.002 in.

Taper (Max.)

0.051 mm

0.002 in.

JR

ENGINE 2.4L DOHC

9 - 87

ENGINE 2.4L DOHC (Continued)

PISTONS

DESCRIPTION

SPECIFICATION

Metric

Standard

Piston Diameter

87.456-87.474

mm

3.4431-3.4439

in.

Clearance @
24.6 mm (0.551
in.) from bottom
of skirt

0.018-0.0516

mm

0.0007-0.0020

in.

Weight

345-355 grams

12.17-12.52 oz.

Land Clearance
(Diametrical)

0.563-0.621

mm

0.022-0.024 in.

Piston Length

66.25 mm

2.608 in.

Piston Ring
Groove Depth
No. 1

3.946-4.045

mm

0.155-0.159 in.

Piston Ring
Groove Depth
No. 2

4.555-4.680

mm

0.179-0.184 in.

Piston Ring
Groove Depth
No. 3

4.108-4.220

mm

0.162-0.166 in.

PISTON PINS

DESCRIPTION

SPECIFICATION

Metric

Standard

Clearance in
Piston

Non-Turbo

0.005-0.018

mm

0.0002-0.0008

in.

Turbo

0.004-0.014

mm

0.0001-0.0005

in.

Clearance in
Connecting Rod

Non-Turbo

Interference

Turbo

0.007-0.018

mm

0.0002-0.0007

in.

Diameter

Non-Turbo

21.99822.003

mm

0.8660-0.8662

in.

Turbo

21.997-22.000

mm

0.8660-0.8661

in.

End Play

Non-Turbo

None

DESCRIPTION

SPECIFICATION

Metric

Standard

Turbo

0.34-1.44 mm

0.0133-0.0566

in.

Length

Non-Turbo

72.75-73.25

mm

2.864-2.883 in.

Turbo

65.41-65.85

mm

2.575-2.592 in.

PISTON RINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Ring Gap-Top
Compression
Ring

0.25-0.51 mm

0.0098-0.020 in.

Wear Limit

0.8 mm

0.031 in.

Ring Gap-2nd
Compression
Ring

0.23-0.48 mm

0.009-0.018 in.

Wear Limit

0.8 mm

0.031 in.

Ring Gap-Oil
Control Steel
Rails

0.25-0.64 mm

0.009-0.025 in.

Wear Limit

1.0 mm

0.039 in.

Ring Side
Clearance-
Compression
Rings

0.030-0.080

mm

0.0011-0.0031

in.

Wear Limit

0.10 mm

0.004 in.

Ring Side
Clearance-Oil
Ring Pack

0.012-0.178

mm

0.0004-0.0070

in.

Ring Width-
Compression
Rings

1.47-1.50 mm

0.057-0.059 in.

Ring Width-Oil
Ring Pack

2.72–2.88 mm

0.107–0.1133

in.

9 - 88

ENGINE 2.4L DOHC

JR

ENGINE 2.4L DOHC (Continued)

CONNECTING ROD

DESCRIPTION

SPECIFICATION

Metric

Standard

Bearing
Clearance

0.025–0.071

mm

0.0009–0.0027

in.

Wear Limit

0.075 mm

0.003 in.

Bore Diameter-
Piston Pin

20.96–20.98

mm

0.8664-0.8667

in.

Bore Diameter-
Crankshaft End

52.993-53.007

mm

2.0863-2.0868

in.

Side Clearance

0.13–0.38 mm

0.005–0.015 in.

Wear Limit

0.40 mm

0.016 in.

Weight-Total
(Less Bearing)

565.8 grams

19.96 oz.

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Connecting Rod
Journal
Diameter

49.984 - 50.000

mm

1.968 - 1.9685

in.

Main Bearing
Journal
Diameter

59.992 - 60.008

mm

2.362 - 2.3625

in.

Journal
Out-of-Round
(Max.)

0.0035 mm

0.0003 in.

Journal Taper
(Max.)

0.007 mm

0.0001 in.

End Play

0.09 - 0.24 mm

0.0035 - 0.0094

in.

Wear Limit

0.38 mm

0.015 in.

Main Bearing
Diametrical
Clearance

0.018 - 0.062

mm

0.0007 - 0.0024

in.

HYDRAULIC LASH ADJUSTER

DESCRIPTION

SPECIFICATION

Metric

Standard

Body Diameter

15.901 - 15.913

mm

0.626 - 0.6264

in.

DESCRIPTION

SPECIFICATION

Metric

Standard

Plunger Travel
Minimum (Dry)

3.0 mm

0.118 in.

CYLINDER HEAD CAMSHAFT BEARING BORE

DIAMETER

DSECRIPTION

SPECIFICATION

Metric

Standard

Journals No.1 -
6

26.020 - 26.041

mm

1.024 - 1.025 in.

CAMSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Journal
Diameter No.
1–6

25.976 - 25.995

mm

1.022 - 1.023 in.

Bearing
Clearance -
Diametrical

0.025 - 0.065

mm

0.0009 - 0.0025

in.

End Play

0.05 - 0.17 mm

0.0019 - 0.0066

in.

Lift (Zero Lash)

Intake

8.25 mm

(0.324 in.)

Exhaust

6.60 mm

(0.259 mm)

Intake Valve
Timing*

Closes (ABDC)

44.3°

Opens (ATDC)

6.2°

Duration

218°

Exhaust Valve
Timing*

Closes (ATDC)

0.8°

Opens (BBDC)

39.9°

Duration

220.7°

Valve Overlap

5.4°

*
All reading in crankshaft degrees at 0.5 mm (0.019
in.) valve lift.

JR

ENGINE 2.4L DOHC

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ENGINE 2.4L DOHC (Continued)

CYLINDER HEAD

DESCRIPTION

SPECIFICATION

Metric

Standard

Material

Cast Aluminum

Gasket
Thickness
(Compressed)

0.71 mm

0.028 in.

VALVE SEAT

DESCRIPTION

SPECIFICATION

Metric

Standard

Angle

44.5 - 45°

Seat Diameter -
Intake

34.37 - 34.63

mm

1.353 - 1.363 in.

Seat Diameter -
Exhaust

27.06 - 27.32

mm

1.065 - 1.075 in.

Runout (Max.)

0.05 mm

0.002 in.

Valve Seat
Width - Intake
and Exhaust

0.9 - 1.3 mm

0.035 - 0.051 in.

Service Limit -

Intake

2.0 mm

0.079 in.

Service Limit -

Exhaust

2.5 mm

0.098 in.

VALVE GUIDE

DESCRIPTION

SPECIFICATION

Metric

Standard

Diameter I.D.

5.975 - 6.000

mm

0.235 - 0.236 in.

Guide Bore
Diameter

11.0 - 11.02

mm

0.4330 - 0.4338

in.

Guide Height
(spring seat to
guide tip)

13.25 - 13.75

mm

0.521 - 0.541 in.

VALVES

DESCRIPTION

SPECIFICATION

Metric

Standard

Face Angle -
Intake and
Exhaust

44.5 - 45°

Head Diameter
- Intake

34.67 - 34.93

mm

1.364 - 1.375

in.)

Head Diameter
- Exhaust

28.32 - 28.52

mm

1.114 - 1.122 in.

Valve Length
(Overall)

Intake

112.76 - 113.32

mm

4.439 - 4.461 in.

Exhaust

110.89 - 111.69

mm

4.365 - 4.397 in.

Valve Stem
Diameter

Intake

5.934 - 5.952

mm

0.2337 - 0.2344

in.

Exhaust

5.906 - 5.924

mm

0.2326 - 0.2333

in.

VALVE MARGIN

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

1.2 - 1.7 mm

0.047 - 0.066 in.

Service Limit

0.95 mm

(.0037 in.)

Exhaust

0.985 - 1.315

mm

0.038 - 0.051 in.

Service Limit

1.05 mm

.039 in.

VALVE STEM TIP

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

48.04 mm

1.891 in.

Exhaust

47.99 mm

1.889 in.

9 - 90

ENGINE 2.4L DOHC

JR

ENGINE 2.4L DOHC (Continued)