Chrysler Stratus Convertible. Manual - part 368

(4) Disconnect

coil

wire

from

distributor

and

secure to good ground to prevent a spark from start-
ing a fire (Conventional Ignition System). For Direct
Ignition System DIS disconnect the coil connector.

(5) Be sure throttle blade is fully open during the

compression check.

(6) Insert compression gage adaptor Special Tool

8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0–500 psi (Blue) pressure
transducer with cable adaptors to the DRBIII

(7) Crank

engine

until

maximum

pressure

reached on gage. Record this pressure as #1 cylinder
pressure.

(8) Repeat the previous step for all remaining cyl-

inders.

(9) Compression should not be less than 689 kPa

(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.

(10) If one or more cylinders have abnormally low

compression pressures, repeat the compression test.

(11) If the same cylinder or cylinders repeat an

abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.

CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST

The combustion pressure leakage test provides an

accurate means for determining engine condition.

Combustion pressure leakage testing will detect:
• Exhaust and intake valve leaks (improper seat-

ing).

• Leaks between adjacent cylinders or into water

jacket.

• Any causes for combustion/compression pressure

loss.

WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.

Check the coolant level and fill as required. DO

NOT install the radiator cap.

Start and operate the engine until it attains nor-

mal operating temperature, then turn the engine
OFF.

Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.

Calibrate the tester according to the manufactur-

er’s instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.

Perform the test procedures on each cylinder

according to the tester manufacturer’s instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.

All gauge pressure indications should be equal,

with no more than 25% leakage per cylinder.

FOR EXAMPLE: At 552 kPa (80 psi) input pres-

sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.

ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS

A leaking engine cylinder head gasket usually

results in loss of power, loss of coolant, and engine
misfiring.

An engine cylinder head gasket leak can be located

between adjacent cylinders or between a cylinder and
the adjacent water jacket.

• An engine cylinder head gasket leaking between

adjacent cylinders is indicated by a loss of power
and/or engine misfire.

• An engine cylinder head gasket leaking between

a cylinder and an adjacent water jacket is indicated
by coolant foaming or overheating and loss of coolant.

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is

leaking between adjacent cylinders, follow the proce-
dures outlined in Cylinder Compression Pressure
Test. An engine cylinder head gasket leaking between
adjacent cylinders will result in approximately a
50-70% reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.

Remove the radiator cap.
Start the engine and allow it to warm up until the

engine thermostat opens.

If a large combustion/compression pressure leak

exists, bubbles will be visible in the coolant.

If bubbles are not visible, perform either of the fol-

lowing procedures:

ENGINE

9 - 13

DIAGNOSIS AND TESTING (Continued)

PRESSURE TEST

• Install cooling system tester Special Tool 7700 or

equivalent, and pressurize the coolant system.

• If a cylinder is leaking combustion pressure into

the water jacket, the tester pointer will pulsate with
every combustion stroke of the cylinder.

CHEMICAL TEST

• This procedure involves using Bloc-Chek Test

Kit, Special Tool C-3685-A or the equivalent. Perform
test procedure following the instructions included
with the test kit.

LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS

A tappet-like noise may be produced from several

items. Check the following items.

(1) Engine oil level too high or too low. This may

cause aerated oil to enter the adjusters and cause
them to be spongy.

(2) Insufficient running time after rebuilding cylin-

der head. Low speed running up to 1 hour may be
required.

(3) During this time, turn engine off and let set for

a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.

(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil

passage to the cylinder head is plugged with debris.

(6) Air ingested into oil due to broken or cracked

oil pump pick up.

(7) Worn valve guides.
(8) Rocker

arm

ears

contacting

valve

spring

retainer.

(9) Rocker arm loose, adjuster stuck or at maxi-

mum extension and still leaves lash in the system.

(10) Faulty lash adjuster.
a. Check

lash

adjusters

for

sponginess

while

installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.

b. Remove suspected lash adjusters, and replace as

necessary.

ENGINE OIL LEAK INSPECTION

Begin with a thorough visual inspection of the

engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:

(1) Do not clean or degrease the engine at this

time because some solvents may cause rubber to
swell, temporarily stopping the leak.

(2) Add an oil soluble dye (use as recommended by

manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to

make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.

(3) Using a black light, inspect the entire engine

for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.

(4) If dye is not observed, drive the vehicle at var-

ious speeds for approximately 24 km (15 miles), and
repeat inspection.

(5)

If the oil leak source is not positively

identified at this time, proceed with the air leak
detection test method as follows:

• Disconnect the fresh air hose (make-up air) at

the cylinder head cover and plug or cap the nipple on
the cover.

• Remove the PCV valve hose from the cylinder

head cover. Cap or plug the PCV valve nipple on the
cover.

• Attach an air hose with pressure gauge and reg-

ulator to the dipstick tube.

CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.

• Gradually apply air pressure from 1 psi to 2.5

psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.

• If the leakage occurs at the crankshaft rear oil

seal area, refer to the section, Inspection for Rear
Seal Area Leak.

(6) If no leaks are detected, turn off the air supply.

Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.

(7) Clean the oil off the suspect oil leak area using

a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.

INSPECTION FOR REAR SEAL AREA LEAKS

Since it is sometimes difficult to determine the

source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.

If the leakage occurs at the crankshaft rear oil seal

area:

(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing

cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is

9 - 14

ENGINE

DIAGNOSIS AND TESTING (Continued)

present in this area, remove transmission for further
inspection.

(a) Circular spray pattern generally indicates

seal leakage or crankshaft damage.

(b) Where leakage tends to run straight down,

possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-

case as previously described.

CAUTION: Do not exceed 20.6 kPa (3 psi).

(5) If the leak is not detected, very slowly turn the

crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.

CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.

(6) For bubbles that remain steady with shaft

rotation, no further inspection can be done until dis-
assembled.

(7) After the oil leak root cause and appropriate

corrective action have been identified, refer to Crank-

shaft Oil Seal—Rear for proper replacement proce-
dures.

ENGINE OIL PRESSURE CHECKING

Check oil pressure using gauge at oil pressure

switch location. Oil pressure should be 41 kPa (6
psi.) at idle or 241 to 517 kPa (35 to 75 psi.) at 3000
RPM.

(1) Remove pressure sending unit and install oil

pressure gauge.

CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM.

(2) Warm engine at high idle until thermostat

opens.

SERVICE PROCEDURES

ENGINE OIL LEVEL CHECK

The best time to check engine oil level is after it

has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.

Checking the oil while the vehicle is on level

ground will improve the accuracy of the oil level
reading. Remove dipstick (Fig. 8), and observe oil
level. Add oil only when the level is at or below the
ADD mark (Fig. 9).

Fig. 8 Dipstick and Engine Oil Fill Locations—2.5L

1 – COOLANT RECOVERY CONTAINER
2 – COOLANT PRESSURE CAP

3 – ENGINE OIL FILL
4 – ENGINE OIL DIPSTICK

ENGINE

9 - 15

DIAGNOSIS AND TESTING (Continued)

ENGINE OIL SERVICE

WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Service Grade Certi-

fied. MOPAR

t provides engine oils that conform to

this service grade.

SAE VISCOSITY

An SAE viscosity grade is used to specify the vis-

cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 10).

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for

gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.

CONTAINER IDENTIFICATION

Standard engine oil identification notations have

been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 11).

ENGINE OIL CHANGE

CHANGING ENGINE OIL

Change engine oil at mileage and time intervals

described in the Maintenance Schedule. Refer to
Group 0, Lubrication and Maintenance.

Run engine until achieving normal operating tem-

perature.

(1) Position the vehicle on a level surface and turn

engine off.

(2) Hoist and support vehicle on safety stands.

Refer to Hoisting and Jacking Recommendations.

(3) Remove oil fill cap. Refer to (Fig. 8).
(4) Place a suitable drain pan under crankcase

drain.

(5) Remove drain plug from crankcase and allow

oil to drain into pan. Inspect drain plug threads for

Fig. 9 Oil Level

1 – ENGINE OIL LEVEL DIPSTICK

Fig. 10 Temperature/Engine Oil Viscosity

Fig. 11 Engine Oil Container Standard Notations

9 - 16

ENGINE

SERVICE PROCEDURES (Continued)

Content .. 366 367 368 369 ..