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Servicq ~Manual
Engine . . . .:I
::L .’
Emission Cont@Systems . . . . . . .-
ION
Chrysler Motors Co ration reserves the right to make changes in
design or to make a27.
ions to or improvemqnts in its products without
imposing any obligations upon itself to install them on its products
previously manufactured.
7
8
9
10
11
12
NOTE
* “Check digit” means a single number or letter X used to
verify the accuracy of transcription of Vehicle identification
number.
[-i!zszEl
1. When repainting original parts, do so after first mask-
ing the theft-protection label, and, after painting, be
sure to peel off the masking tape.
2. The theft-protection label for replacement parts is cov-
ered by masking tape, so.such parts can be painted
OOAO213
as is. The masking tape should be removed after palnt-
(10000222
lng is finished.
3. The theft-protection label should not be removed from
original parts or replacement parts.
16 INTfiQDt~JJCTION’ r ,Vbhicie 4dentification
LOCATIONS
Target area (A: for original equipment parts, B: for replacement parts)
Engine
<Non-turbo> <Turbo>
Manual transaxle
eNdi%turbot <Turbo>
A
oO”oo1.
00003678
00x0092
Automatic transaxle
<Non-turbo> <Turbo>
100 mm
6
WOO3679
ooA0.t~
Target area (A: for original equipment parts, B: for replacement parts)
Fender Door
31x0521 00003660
\’ t
Hood Liftgate
6 ,: A
31xo4ra
00003661
INTRODUCTION.+y Vehicle I&#tification/Ptie,@autipw before Service ~~ t:
’
Target area (A: for original equipment parts, B: for replacement parts)
00003662
00X0016
00x01073
_
GENERAL SPECIFICATIONS
<FWD> -,
Seating capacity 4 4
TIGHTENING TORQUE
Each torque value in the table is a standard value The values, in the table are not applicable:
for tightening under the following conditions. (1) If toothed washers are inserted.
(1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
and plated with zinc. (3) If bolts are tightened to plastic or diecast in-
(2) The threads and bearing surface of bolts and serted nuts.
nuts are all in dry condition. (4) If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque
Bolt nominal diameter Pitch (mm) Torque Nm (ft.lbs.)
(mm)
Head mark “4” Head mark ‘7” Head mark “8”
M5 I
0.8 I
2.5 (1.8) I
4.9 (3.6) I
5.9 (4.3)
M6 1.0 4.9 (3.6) 1 8.8(6.5) 9.8 (7.2)
1 12(8.7) 1 22 (16) 1 25 (18)
Ml0 1.25 24 (17) 44 (33) 52 (38)
Ml2 1.25 41 (30) 8i' (60) 96(71)
Ml4 1.5 72 (53) 137(101) 157(116)
I I I
GENERAL INFORMAtION
Items Specifications
Type In-line OHV, DOHC
Number of cylinders 4
Bore mm (in.) 85.0 (3.35)
Stroke mm (in.) 88.0 (3.46)
Piston displacement cm3 (cu.in.) 1,997 (121.9)
Compression ratio 8.5
Firing order l-3-4-2
Counterbalance shaft Equipped
Valve timing Intake valve Opens 21 “BTDC ” .
Closes 51 “ABDC
Exhaust valve Opens 57”BBDC y I;,.
Closes 15”ATDC - , ;
Camshaft
Counte~alance shaft
Oil jet w
2.OL ENGINE <TURBO, L .Setiice Specifications
SERVICE SPECIFICATIONS
Items 1 Standard
Standard value 1 LimitLimit I
Drive belt Tension NN (Ibs.)
(tbs.) When checked 245 - 490 (55.1 - 110.2) -
(For generator) When a new belt is installed 490-686 (110.2 -154.3) -
When a used belt is installed 392 (88.2)
Deflection 1 When checked I 9.0-11.5(.35-&j) ( -
mm (in.) When a new belt is installed
<Reference
value> When a used belt is installed
Drive belt
(For power
steering pump)
Drive belt
(For A/C
compressor)
Valve sprin .+
i! (It%:)/ iini. (in.) 245 (54)/4-0.0 (1.57) I ” “*
Valve seat
. . guide ,
Valve
Prbje&@r+dr
s-.~i-.~.-ti.~ii
: .,
Oij +I@. Side clearance 9.96N39.!4 (9031
0.06 - 0.12 LO024
78 (11.4).or more
Piston
Piston ring
iPEClAL TOOLS
TooI _. :- Tool number and nan@ $%@a&d b y M i l l e r *j Application
toothumber
MB991 502 DRB-III Scan tool I idle speed inspection’
Scan tool
(MUT-II) ;;;- ::
I L
.I
. . ,,
,.. I/
: A’-
. ^ ..-,. I__.-__:.. .- _... .._--__., .I.,^ , ,_ _
I
..,. .-._” ____,,,
I
*... _ .-,. _. - --..-y--“, .I_ .I
Tool number and nami
MD998781
Flywheel stopper
MD998778
MB990938
~-----
Handle
GENERAL SERVICE
TOOL
MZ203827
Engine litter
MB991 453
‘En$&th;anger .
assembly
-.
MD998767 MD998767 I : -:~&~~~~~~ ,+to ;tensioner installation
Tensioner pulley
wrench
MD998778
Crankshaft sprocket
puller
MD998782
,I.
Valve litter :< set
Ii ,, _ ..- _ . . b._ ,... . . . _. “.
I+:.? : :,
MB990767
Tool’number
_di.L_ /- and name Replaced by Miller
I tool number
Ml$9:j193 General service tool $@vehting for&in substances
(Use shop towel) fro’m; riteri$transfer
Plug ~$vJl 6,j ,;,
‘MD9981 62 MD9981 62
PI& wrench
,_
,‘i
MD998285 i-”:3-.
I-
-)
Leak-down tester
Application ioifi
. ..- ,,,...
. .-..
‘,.,.,! t
,i. r _
/
II
‘I ,-. ., :
! i , ’
SW-28 2.OL ENGINE <TURBO> - CrankdibfttPirlf@
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
Pre-removal Operation
s l Under Cover Removal
(Refer to GROUP 23A - Under Cover.)
AOlX0179
Removal steps
1. Drive belt (Generator)
2. Drive belt (Power steering)
3. Drive belt (A/C)
4. Crankshaft pulley
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
Pm-removal Operation
lTiming Belt Front Upper Cover Removal
(Refer to P.QA-42.) h Timing Belt Front Upper Cover Installation
2.9 Nm 3
2.2 Fibs. bs.
16
4.9 Nm
OlNOO42
3.6 ft.lbs.
Engine oil
Slits 01 A0048 I
NOTE
Install new camshafts using the following procedure.
(1) Remove the rocker arms.
(2) Lay the camshafts on the cylinder head and install
the bearing caps.
(3) Check that the camshaft can be easily turned by
hand.
(4) After checking, remove the bearing caps and the
camshafts, and install the rocker arms.
- - -.Nm
4.9 ..
2.9 Nm 18
,?w 8
12 -r65/ -2
ii!%- 25
Engine oil
01x0199
Removal steps ”
1. Accelerator cable connection 14. Camshaft position sensor connector
$Iyfi;ot; GROUP 14F-On-vehicle 15. Crankshaft position sensor
connector
2. Air hose C 16. Air conditioning compressor
3. Idle air control motor connector connector
4. Knock sensor connector 17. Control wiring harness
5. Heated oxygen sensor connector 18. Center cover
6. Engine coolant temperature gauge 19. Spark plug cable
unit connector 20. Brake booster vacuum hose
7. Engine coolant temperature sensor connection
connector FE+ 21. High-pressure fuel hose connection
8. Ignition power transistor connector 22. Fuel return hose connection
9. Throttle. position sensor connector 23. B -pass valve hose connection
10. Capacitor connector 24. VY ater hose connection
11. Manifold’ differential pressure 25. Vacuum “hoses connection
sensor connector 26. Breather;hose connection
12. Injector;,connectors 27:. RX h o s e .connection
13. tgnition icoil connector ,., .,!, a’:., < :; /, ‘, .,
2.OL- ENGINE <TURBO> - Cylinder Head Gasket
++90” -++90” 11
I A
(58 ft.lbs.+O Ribs.+15 ft.lbs. a
++90” ++90”) /34 3 6
\ “-
I/ -
-34 Nm
-25 ft.lbs.
&eclfled sealant:
MITSUBISHI GENUINE PART
Sealant: MOPAR Part No. 4318034 or equivalent MD970389 or equivalent
AllAOllO
9A950 2.0L ENGINE ;clTlJRBO,~ 3Mishaft and Rock& Arms
t’
11 I
12
6ENl079
Removal steps
1. Plate ,C+ 8. Bearing cap No. 3
FE+ 2. Camshaft oil seal .C+ 9. Bearing cap No. 4
.D+ 3. Circular packing ,B+ 10. Camshaft
bC+ 4. Bearing cap front 11. Rocker arm
W+ 5. Bearing cap rear .A+ 12. Lash adjuster .
Wq 6. Bearing cap No. 2 13. Oil delivery body
bCi4 7. Bearing cap No. 5
INSTALLATION SERVICE POINTS
,A4 LASH ADJUSTER INSTALLATION
(1) Immerse the lash adjuster in clean diesel fuel.
(2) Using the special tool (MD998442), move the plunger
up and down 4 or 5 times while pushing down lightly
on the check ball to bleed out the air.
atNO
W’ S’it
one. The intake camshaft has a slit on its rear end for
driving the crankshaft position sensor.
intake side
t’ Dowel pin (3) Install the crankshaft sprocket B or spacer and flange
to an end of the crankshaft. Then turn the crankshaft
until the timing marks are lined up to set No.? cylinder
to the TDC.
(4) Set the camshafts so that their dowel. pins are positioned
at top.
:
04 Capnumber
Only “L” or “R” is stamped on No. 1 bearing cap. Cap
No. is stamped on No. 2 to No. 5 bearing caps, No.
6EN0464
W Camshaft sprocket side (2) Tighten the bearing caps in the order shown two to three
11 9 7 8 10 12 times. Tighten to specification in the final sequence.
(3) Check that the rocker arm is held in position on the lash
adjuster and valve stem end.
53 12 48
6EN0192
2.OL ENGINE <TURBO>-- CamshMtiatid Robket Arms’
r
.E+ CAMSHAFT OIL SEAL INSTALLATION
INSPECTION
CAMSHAFT
(1) Measure the cam height.
Standard value: 34.91 mm (1.37 in.) .,
Limit’: 34.51 mm (1.35 in.)
9ENOO58
ROCKER ARM
(1) Check the roller surface. If any dents, damage or seizure
is evident, replace the rocker arm.
(2) Check rotation of the roller. If it does not rotate smoothly
or if looseness is evident, replace the rocker arm.
(3) Check the inside diameter. If damage or seizure ,is evident,
replace the rocker arm.
6ENOl85
1’ Division = 1 mm LO39 in.1 (4) After air bleeding, set lash adjuster on the special tool
(Leak down tester MD998440).
(5) After plunger has gone down 0.2 to 0.5 mm (908 to
MD99 .020 in.), measure time taken for it to go down 1 mm
L (.039 in.). Replace if measured time is out of specification.
Standard value: 4-20 seconds/l mm (.04 in.)
[Diesel fuel at M-20’% (59~68”F)j
7ENO438
Lash
adjuster
2.OL -ENGINE <TURBO> - CylintW He& ti&$Val\ie -
I
:m’1 Lubricate all internal
parts with engine oil
during reassembly.
I
6EN0948
Removal steps
a, .C+ 1. Cyljnder head bolt 11. Exhaust valve
;. C&knkrn head assembly 1:: ,A+ 12. Valve stem seal
13. Valve spring seat
.B+ 4: Retainer lock +C, .A+ 14. Valve stem seal
5. Valve spring retainer 15. Valve sprin,g seat
6. Valve spring 16. Intake valve guide
4W 7. Intake valve 17. Exhaust valve guide
.B+ 8. Retainer lock 18. Intake valve seat
9. Valve spring retainer 19. Exhaust valve seat
IO. Valve spring 20. Cylinder head
r _‘, . . .
ON-VEHICLE INSPECTION OF MFI COMPONENTS
COMPONENT LOCATION
Name \>ylll”“l ,“a I Ici “J”‘LN’
Air conditioning compressor clutch relay A Ignition timing adjustment connector E
Air conditioning switch W Injector R
Camshaft position sensor N Knock sensor L
Check engine/Malfunction indicator lamp U Manifold differential pressure (MDP) sensor
H
Crankshaft position sensor 0
Data link connector V Multiport fuel injection (MFI) relay Y
EGR solenoid J Park/Neutral position switch T
Engine control module (ECM) X Power steering pressure switch P
Engine coolant temperature sensor D Resistor I
Evaporative emission purge solenoid J Throttle position sensor (with built-in closed
throttle position switch) G
Fuel pressure solenoid M
Fuel pump check terminal E Turbocharger waste gate sol8noid S
Fuel pump relay Y Vehicle speed sensor C
Heated oxygen sensor (Front) Q
Heated oxygen sensor (Rear) 2 Volume air flow sensor (with built-in intake air
Idle air control motor F temperature sensor and barometric pressure B
sensor)
Ignition coil (IgnitiQh powentransistor) K
NOTE
The “Name” column is in alphabetical order.
6FU2077
6FU2078
6FU248o
MFI, <TURBO>.“L On-vehicle Inspectbn of MFI C&ii~ier;i@i ’ ‘f’#sesg
. *
-I
//L
Idle air control motor-
, (stepper motor)
14A-240 MFI <TURBO>. 9’. On-vehici~~;In’specti~n of MFI ;CiirQYdneri& ”
Intake side
camshaft
sprocket
l&j#3&l
MFI <TURBO> - On-vehicle: ins@dtik;~6f .-MFi Components
;
14F-10 FUEL SUPPLY AND ENGINE CONTROL - Accelerator Cable And P&M
SERVICE SPECIFICATION
Item Standard value
Accelerator cable play mm (in.) l-2 (.04-.08)
LUBRICANT
Item Specified lubricant Quantity
Accelerator pedal pin, spring MOPAR Multi-mileage Lubricant Part As required
accelerator cable end No. 2525035 or equivalent
TROUBLESHOOTING
21
3
Symptom Probable cause Remedy
Throttle valve will not Misadjusted accelerator cable Adjust
fully open or close
Misadjusted auto-cruise control cable Adjust
Broken return spring Replace
Throttle lever malfunction Replace
Accelerator pedal op- Accelerator pedal wrongly tightened Repair
eration not smooth
(over acceleration) Misinstalled accelerator cable Repair
Accelerator cable requires lubrication Lubricate or replace
ON4EHICLE SERVICE
ACCELERiTOR CABLE CHECK AND
ADJUSTMENT
For models equjpped with the auto-cruise control system,
refer to GROUP 14G - On-vehicle Service.
1. Turn AIC and lights OFF.
inspect and adjust at no load.
2. Warm engine until stabilized at idle.
3. Confirm idle speed is at prescribed rpm.
4. Stop engine (ignition switch OFF).
5. Confirm there are no sharp bends in accelerator cable.
6. Check inner cable for correct slack.
7. If there is too much slack or no slack, adjust play by
the following procedures.
(13:Turn the ignition switch to the ON position (without
starting the engine) and leave in that condition for
.approximately 15 seconds in order to initialize the
IAC motor.
i: (,/.
14F-12 FUEL SUPPLY AND ENGINE CONTROL ‘- iGcelerator &6i’iiCA8d,@&@
4.9
3.6
4.9 Nm
3.6hlbs.l
<Non-turbo>
4.9 Nm
3.6ftlbs.
11
13 Nm
/ 9.4 ft.lbs.
Grease:
MOPAR Multi-Mileage Lubricant
Part No. 2525035 or equivalent
4.; Nm
3.6ft.lbs.
Bumper
INSTALLATION SERVICE POINT
(small) Bumper
(large) 17 m m ,A4 BUMPER INSTALLATION
Install the bumper as shown in the diagram.
10x0722 ,’
t**.
18X0721
00000130
“I
INSPECTION
HOOD SWITCH CONTINUITY CHECK _, _ ,;x.,
18X0831
mm (in.) 00000129
:
FENDER
SEALANTS
Items Specified sealants
Fender to body panel MOPAR Silicone Rubber Sealer Part No. 4026070 or equivalent
I Splash shield to fender MOPAR Silicone Rubber Sealer Part No. 4026070 or Auto Glass
Adhesive and Sealer Part No. 2298825 or equivalent I
FENDER
REMOVAL AND INSTALLATION
Prwemoval and post-installation Operation
Front Bum r Removal and Installation
(Refer to ge
.23A-71.)
10x0734
Sealant:
MOPAR Silicon Rubber Sealer Part No.
4026070 or Auto Glass Adhesive and Sealer
Part No.2298825 or equivalent
18X0736
18X0729
Sealant:
MOPAR Silicon Rubber Sealer Part No.
4026070 or equivalent
00000131
Removal steps
1. Splash shield :
l S@e air cjam (Refer to P.23A-79)
i. Front fend& panel
,,,- eODY - Fend&
FENDER
SEALANTS
I t e m s Specified sealants
I Fender to body panel I MOPAR Silicone Rubber Sealer Part No. 4026070 or equivalent I
I Splash shield to fender MOPAR Silicone Rubber Sealer Part No. 4026070 or Auto Glass
Adhesive and Sealer Part No. 2298825 or equivalent
FENDER
REMOVAL AND INSTALLATION
Preremoval and post-installation Operation
Front Bum r Renioval and installation
(Refer to B”
.23A-71.)
18X0734
Sealant:
MOPAR Silicon Rubber Sealer Part No.
4026070 or Auto Glass Adhesive and Sealer
Part No.2298825 or equivalent
18X0736
18X0729
Sealant:
MOPAR Silicon Rubber Sealer Part No.
4026070 or equivalent
00000131
Removal steps
1. Splash shield
l Side air dam (Refer to P.23A-79)
2. Front fender panel
g?&p:
*
BODY i Front Bumper
’
‘!$
FRONT BUMPER
REMOVAL AND INSTALLATION
Prs-removal and Post-installation Operation
S lash shield Removal and Installation
&efer to GROUP 23A-61.)
Removal steps
1. Fog light ;. Fc$t bumper corner plate
2. Front side-marker light
3. Front bumper center plate 7: Front fascia bracket
4. Front bumper assembly
23A-72 BODY - Pro’nt Biimper-
Disassembly steps
1. Fog light hole cover 5. Front bumper reinforcement
2. Front license plate bracket 6. Front bumper core
3. Bolt plate 7. Front bumper stay assembly
4. Front bumper side plate 8. Front bumper face
REAR BUMPER
REMOVAL AND INSTALLATION
~16x0676
Removal steps
1. Rear panel garnish 5. Connector harness
2. Rear combination light 6. Rear bumper assembly
3. Rear bumper upper plate (A) 7. Rear bumper side plate
4. Rear bumper upper plate (B)
BODY<- Rear Burnber
Alox1oos
Disassembly steps
1. Rear bumper lower plate 4. Rear bumper stay assembly
2. Rear bumper reinforcement 5. Rear bumper face
3. Rear bumper core
BODY -; ~GarnisheS
GARNISHES
REMOVAL AND INSTALLATION
13Nm
18X0675
00003740
Front deck garnish removal steps Rear panel garnish removal steps
1. Wiper arm assembly l Rear end trim
2. Front deck garnish (Refq to P.$JA-90)
3. Rea? ,-panel garnish
23A-76 BODY, ‘- Moldings
MOLDINGS
SEALANT AND ADHESIVE
Items Specified sealant and adhesive
Side protector molding 3M ATD Part No. 6382 or equivalent and
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
MOLDINGS
REMOVAL AND INSTALLATION
Adhesive tape:
3M ATD Part No. 6382 or equivalent
15 mm (59 in.) wide and 1.2 mm (.047 in.) thick
Adhesive:
3M ATD Part No. 8606 Super Fast Urethane Primer or equivalent
(2) Insert fishing line [0O.8 mm (.03 in.)] in between the body
Fishing line and the side protector molding, pull both ends alternately
\ I to cut the adhesive section and remove the side protector
molding.
Caution
1. When reusing the side protector Molding, pull the
fishing line along the edge of the body so as not
to damage the edge of the side protector Molding.
2. If the adhesive Is difficult to remove, heat it to
40°C (104°F).
Aesin spatula
Al8XO607
AERO PARTS
SEALANT AND ADHESIVE
I
Items Specified sealant and adhesive
Door garnish, Side air dam 3M ATD Part No. 6382 or equivalent and
3MATD Part No. 8608 Super Fast Urethane Primer or equivalent
AERO PARTS
REMOVAL AND INSTALLATION
Adhesive tape:
3M ATD Part No. 6382 or equivalent
4 mm (.15 in.) wide and 1.5 mm (.059 in.) thick
Adhesive:
3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
18X0673
00003751
nm (in.) - 10x0133