CONTENTS

CAMSHAFT AND CAM FOLLOWER ............ 28 INTAKE MANIFOLD “..............r.................... 25

‘I\
COOLING SYSTEM COMPONENTS ............. 21 OIL PAN AND 0l.k PUMP . . , . . . . . . . . . . . . . . . . . . . . . . i. .: 39 ,. _ .
,’:1 (’ :
CRANKSHAFT ............................................ 55 OIL PUMP ,,,.~......,...*.....**................-.....-... 4%

CYLINDER HEAD AND VALVE .................... 32 PISTON, CONNECTING ROD I AND., “’ ’ :

. ..I.............. .).45
CYLINDER BLOCK . . . . . . . . .. .. ~ . . . . . . . . . _.
EXHAUST MANIFOLD ................................. 27
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FUEL AND EMISSION CONTROL PARTS ... .23
SPECIFICATIONS ,......,.................,.............. 3
GENERAL INFORMATION ............................. 2 Sealants _. . . . . . . . . . . . . . . . . . . . . . 7
General Specifications ................................. 2 Service Specifications.. . . . . . . . . . . . . . . 3
Torque Specifications . . . . . . . . . . . . . . . . . . 6
GENERATOR .............................................. 11
TIMING BELT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e..... 16
IGNITION SYSTEM ...................................... 12
llD-2 ENGINE OVERHAUL <2.0L (420A)> - General Information
11 ) li I’
GENERAL INFORMATION
GENERAL SPECIFICATIONS
Descriptions Specifications

Type In-line OHV,’ DOHC

Number of cylinders 4 I,.”
Cylinder bore mm (in.) 87.5 (3.445) .?
Piston stroke mm (in.) 83.0 (3.267)
c
Compression ratio 9.6
,’
Valve timing Intake valve Opens (BTDC) 1.3”
[Measured at 0.5
mm (.02 in.) lift] Closes (ABDC) 39.7”
Exhaust valve Opens (BBDC) 36”
Closes (ATDC) 1.1 o ! /I,!, I

Lubrication system Pressure feed, full-flow filtration, ) 1.

Water pump type Centrifugal impeller type .,
EGR type Single type ‘.,
Injector type and number Electromagnetic, 4
“I ,*

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 ENGINE OVERHAUL <2.0L (420A)> ‘+ Spbcificaths

SPECIFICATIONS ll~lb

SERVICE SPECIFICATIONS , ,,,‘y” ‘i :,

Items Standard value Limit
Ignition coil system
Spark plug cable resistence Q 3000- 12000 _ : I, ,(, ^( / 1

Ignition coil resistence SL Primary 0.51-0.61

Secondary 11500-13500 -
Camshaft and cam follower .’ b ‘.
Cam wear amount mm (in.) 0 . 0 2 5 4 (.OOl) 0.254 (.Ol)
Camshaft bearing bore diameter mm (in.) 26.020-26.041 - .” ‘^
(1.024-1.025)
Camshaft diameter bearing clearance mm (in.) 0.069-0.071
(.0027-.0028) -
Camshaft end play mm (in.) 0.15 (.006), - *‘. :
Camshaft bearing journal diameter mm (in.) 25.951-25.970 -
(1.0217-1.0224)
Camshaft lift mm (in.) Intake 8.22 (.324)
.
Exhaust 7.00 (.276) -.
Hydraulic lash adjuster mm (in.) Body diameter 2 2 . 9 4 9 - 2 2 . 9 6 2 -
(9035-9040)
P I ,. _‘ 3,
Plunger travel 4.24 (.167)
minimum (dry)
,.‘1 I
Zylinder head and valve
:latness of gasket surface mm (in.) - ., r 0.1 (.0&t), ‘.

falve seat angle 44.5” -45” - ”L

falve seat runout (max) mm (in.) 0.050 (902) ..I c ,,- I

ralve seat width (Finish) mm (in.) 0.9-1.3 (.035-.051) - ** :,

ralve seat guide bore diameter mm (in.) 11.00-11.02 I’ - . “> ., 1

(.4330-.4338) ,-_ I,
Itake valve seat diameter mm (in.) 34.50 (1.358) -
I .,
ixhaust valve diameter mm (in.) 29.50 (1.161) -
‘alve face angle 45”-45.5” .-
_/,,
‘alve head diameter mm (in.) Intake 34.67-34.93
(1.364-1.375) - ’ i. ri : *.I
Exhaust 30.37-30.63
(1.195-1.205) - ‘ .-,
.i

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11D-4
__- _ ENGINE
-..-...- -OVERHAUL t2BL\ l42OAb
.,-. . . . . .-- ----- ---- -,- - Saecificatiaris
-r--...---.-..-

Items Standard value Lim it j

Valve margin mm (in.) intake 1.285-I’.615 _ ” ’ ‘,A ‘, ;$i,

(.050-.OSS)
, >’
Exhaust 0.985-l .315 ,
(.038-.&jl) :,I ‘~ : ’
Valve length (Overall) mm (in.) Intake 111.49-111.99 -
(4.389-4.409)
Exhaust 109.59-110.09 -
(4.314-4.334)
Valve stem tip height mm (in.) Intake 48.04 (1.891) A .j .,

Exhaust 47.99 (1.889) - r *

Valve stem diameter mm (in.) Intake 5.934-5.952 _. ‘: , ,
(.233- .234) -
Exhaust 5.906-5.924
(.233-.233) -
Valve stem to guide clearance mm (in.) Intake 0.048-0.066 0.076 (903) ’
(.OOl g-.0026)
Exhaust 0.074-0.094 0.101 (.004)
(.0029-.0037)
Jalve guide inner diameter mm (in.) 5.975-6.000
(.2352-.2362) -
Jalve spring free length mm (in.) 46 (1.811) -
/alve spring tension (valve closed) N/mm (Ibs./in.) 246-270/38.0 -
(55-60/l .496)
lalve spring tension (valve open) N/mm (Ibs./in.) 549-611129.3 -.
(123-137A.153) ‘I .,

/alve spring number of coils mm (in.) 7.35 - ‘I . 3 .-:

falve spring wire diameter mm (in.) 3.76 (.148) - ^, .ji

Ialve installed spring height mm (in.) 38.00 (1.496) - ”

Xl pump ,. ”

Xl pump clearance over rotors mm (in.) 0.102 (.004) c:.

)il pump cover out of flat mm (in.) 0 . 0 7 6 $003)
1,
Xl pump inner rotor thickness mm (in.) 7.64 (301)
.’ I_
)il pump outer rotor clearance mm (in.) 0;39 (.015)
ril pump outer rotor diameter mm (in.) 79.95 (3.148)
ril pump outer rotor thickness mm (in.) 7.64 (301)
ril pump tip clearance between rotors mm (in.) - 0.02 (.0008)
3il pressure at curb idle speed kPa (psi) .
25 (4)

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 ENGINE OVERHAUL <2.0L (420A)> A Specifications
. -
Items Standard value Limit
Piston, connecting rod and cylinder block , !I /

Piston standard piston size mm (in.) 87.463-87.481 -

(3.4434-3.4441)
Piston to bore clearance mm (in.) 0.012-0.044
(.0005-.0617) - ;
From bottom of skirt mm (in.) 0.012-0.044
(.0005-.0017) . -
Land clearance (Diametrical) mm (in.) 0.740-0.803
(.029-.032) -
Piston length mm (in.) 63.82 (2.51-3) -
Piston ring groove Top upper compression ring 3.983-4.132
depth mm (in.) (.157-.163) -
Intermediate compression ring 4.456-4.605 .
(.175-.181) - :I_
, 1.
Oil control (Steel ring) ring 3.841-4.075
(.151-.160) -
, ;;
Piston pin clearance in piston mm (in.) 0.008-0.020
(.0003-.0008) - ”
Piston pin in rod (interference) mm (in.) 0.018-9.043 /I -
(.0007-.0017)
‘iston pin diameter mm (in.) 20.998-21.003 2 - :- I
(.8267-.8269)
‘iston pin length mm (in.) 74.75-75.25 - ?- -’ >
(2.943-2963)
‘iston ring gap mm Top upper compression ring 0.23-0.52 0 . 8 (.031)
‘in.) (.009- .020)
Intermediate compression ring 0.49-0.78 1 .o (.039)
(.019;.031)
Oil control (Steel ring) ring 0.23-0.68 1 .o (.039)
(.OOS-.026)
‘iston ring side Top upper and intermediate compression ring 0.025-0.065 ‘0.10 (604)
:learance mm (in.) (001 O-.0026) ., I
Oil control (Pack) ring 0.004-0.178 - ” ” ’
(.0002-.0070)
‘,
‘iston ring width mm Top upper and intermediate compression ring 1.17- 1 .19
n.) (.046-.047) - . , ’
,” “’
Oil control (Pack) ring 2.854-3.008
(.1124-.1184) - .I’
Cylinder block cylinder bore diameter mm (in.) 87.5 (3.445) / 1 ‘ ‘i

Cylinder block cylinder bore out-of-round mm (in.) 6.051 (662) b

Cylinder block cylinder bore taper mm (in.) 0.051 (992) ‘: .

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11 D-6 ENGINE OVERHAUL <2.0L (42OA)> - Specifications

Items Standard value Limit i! r

Connecting rod bearing oil clearance mm (in.) 0.026-0.059 * ,6.075 (.01,5) 7” I 1 I

(.OOlO-.0023) ,, : 1 1
Connecting rod piston pin bore diameter mm (in.) 20.96-20.98
(.8252-.8260) -
Connecting rod large end bore diameter mm (in.) 50.991-51.005 -
(2.0075-2.0081)
Connecting rod side clearance mm (in.) 0.13-0.38 0.37 (.015)
(.0051-.0150) . i
Main bearing journal diameter mm (in.) 51.9924-52.0076 -
(2.0469-2.0475)
I “,
Main bearing journal out-of-round mm (in.) - 0.0035 (.OOOl)
.
Main bearing journal taper mm (in.) - 0.0038 (.OOOl) ‘: i
Crankshaft
Crankshaft connecting rod journal diameter mm (in.) 47.9924-48.0076 -
(1.8894- 1.8900)
Crankshaft out-of-round mm (in.) 0.0035 (.OOOl)
J
Crankshaft tape mm (in.) 0.0038 (.OOOl)
Crankshaft main bearing diameter clearance mm (in.) 0.022-0.062 1 1 I ’”.
(.OOOS-.0024)
Crankshaft end play mm (in.) 0.09-0.24 - ’ :
(.0035-.0094)

TORQUE SPECIFICATIONS
Items
Generator
Pivot
Lock nut 1 61 144
Ignition system
Spark plug 28 20
Camshaft position sensor 3 2.2 ., ‘I >s
Timing belt t!
Crankshaft damper bolt 62 45
Engine mount bracket 41 30
Timing belt inspection cover 12. 9.7 ;;
Tensioner pulley 28 20
Timing belt tensioner 31 22
Tensioner arm bracket 31 22
Camshaft sprocket 101 73 “>: I i
Rear timing belt cover 9.6 q.9
Cooling system components
Water pump 112 .~“g~ >‘I
Thermostat housing 22 16

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 ENGINE OVERHAUL <2.0L (42OA)> - Spbcificatiork

Items
Engine coolant temperature sensor
Fuel and emission control parts
EGR tube 11 ” 8
EGR valve 22’ ‘,16-’ ’
Intake manifold : ” I : ,j
I

Intake manifold air temperature sensor 7 ” ‘-5, $..,i,

Manifold absolute pressure sensor 2 1 . 4
Intake manifold 23 1 7 :
Exhaust manifold
Exhaust manifold 1 23 ] 17
Camshaft and cam follower
Cvlinder head cover I 12 19 ‘L ,I
Bearing head cover No. 2,3,4, 5 12 ,9 ,’
No. 1, 6 28 20 ,‘,, ._
Cvlinder
-a head and valve .
Cylinder head bolt Long bolt 87 + l/4 turn 48?1/4tum ‘.
Short bolt 28 + l/4 turn 20 * .<I/4 t:um ;
,.- ”
Oil pan and oil pump
Oil filter 21 , 15 ,I
Adapter 55 40;.
Oil Dan 12 ‘J.9 i
I

Oil pick-up tube 2 8 (20 ‘):

Oil pump 1 23 “_ 1 17 ‘: II
Oil pump i- ,., “3
Relief valve retaining cap 1 54 [‘39 .i
Oil pump cover 1 12 1 Q :i,’ j
Piston, connecting rod and cylinder block 1.
Connecting rod cap bolt 27 + l/4 turn 20 + l/4 turn
Knock sensor ) 10 17 I
SEALANTS llaooo~

Specified sealant
Engine coolant temperature sensor Loctite 24200 or equivalent
Therm0 switch Loctite 24200 or equivalent
Camshaft bearing cap No.1, No.6 Loctite 51817 or equivalent
Oil pump Loctite 51817 or equivalent
Bed plate to oil pan gasket Loctite 18718 or equivalent
Oil pressure switch Loctite 24200 or equivalent
I
Bed plate to cylinder block Loctite 19614 or equivalent

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 110-8 ENGINE OVERHAUL <2.0L (420A)> - Specificlticins
_.-
FORM-IN-PLACE GASKETS &Oi8lOiJlCl

There are numerous places where form-in-place gaskets are used on the engine. Care must be @ken
when applying form-in-place gaskets to assure obtaining the desired results. Beacl size, continuity, ‘and
location are of great importance. Too thin a bead can result in leakage while too much can result’ in
spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width i-s
essential to obtain a leak-free joint. i
GASKET DISASSEMBLY 1’.
Parts assembled with form-in-place gaskets may be disassembled without unusual effort’ In’soine instafices,
it may be necessary to lightly tap the part with a mallet or other suitable tool to break the seal between
the mating surfaces. A flat gasket scraper may also be lightly tapped into the joint but care must be
/’
taken not to damage the mating surfaces.
‘,. /
SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces removing all loose material. Inspect st&tped p&s’to
assure gasket rails are flat. Flatten rails with a hammer on a flat plate if reqtired.’ G&&et su’&ices
must be free of oil and dirt. Make sure old gasket material is removed from blind attachiq bores.
FORM-IN-PLACE GASKET APPLICATION \ a.+ j ,I
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gaskets.
Gasket material should be applied sparingly 1 mm (.040 inch.) diameter or less of’sealant to one g&ket
surface, Be certain the material surrounds each mounting hole. Excess material can easily be wiped
‘off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended
during assembly, to prevent smearing the material off location.
Loctite 18718 gasket material or equivalent should be applied in a continuous bead ~approximately 3
mm (.120 inch.) in diameter. All mounting holes must be circled. For corner sealing, .a 3.17 or 6.35
mm (l/8 or l/4 inch.) drop is placed in the center of the gasket contact area. Uncured sealant may
be removed with a shop towels. Components should be torqued in place while the sealant is’stilt wet
to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to
prevent smearing of material off location.
MOPAR TORQUE CURE GASKET MAKER
Mopar torque cure gasket maker is a unique anaerobic type gasket material to be used ONLY betvveen
the bedplate and engine block. The material cures in the absence of air when. torqued between two
metallic surfaces. It will not cure if left in the uncovered tube. This anaerobic material 1s specially made
to seal the area between the bedplate and cylinder block without disturbing the bearing’ cleat%nce or
alignment of these components. 1. . ...p..*/i” .
:‘“:i. ’ ~/
i I ;

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 ENGINE OVERHAUL <2.0L (42OA)i - Spbcid’T6olb

SPECIAL TOOLS
“,
Tool Tool number and name Supersession Application
MB995057 6827-A Removal of,jcrankshaff damper
Removal and crankshaftsprocket
crankshaft ,. *
damper/sprocket
cd@) ‘,.
8995057

MB995055 1026 Removal of crdnksshaft

> damper.
Removal
puller damper

., :
MB995035 C-4685-C Installation of crankshaft damper
Installer ‘and crankshaft spri&et. i”.I
_,:
damper/sprocket

MB990767 MB990767-01 Holding camshaft sprocket when

End yoke holder loosening or turquing bolt.

MD99871 9
Pin (2)

1 1
PB 63 i

MB995026 6792 Installation of crankshaft

Installer sprocket.
crankshaft
c; sprocket
0

MB995027 6793

&5@!$?2> L%YJ&fi

MD99871 3 Installation of crankshaft seal.

Installer
9 camshaft oil
seal
(9
CQ

MB995022 6780- 1
Installer
crankshaft seal

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IID-IO ENGINE OVERHAUL <2.0L (420A)> - Special Tools

crankshaft seal

MB995059 6926-l Installation of crankshaft oil seal

0 -.:
8 *
El995059

MB995060 6926-2

8995060

,. ,.
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ENGINE OVERHAUL <2.0L (42OA)> - Generator

GENERATOR 1120182uo12
.'
,‘i
REMOVAL /
(1) Remove drive belt. ’ j :.‘,
(2) Remove generator.
(3) Remove generator bracd.i ’ I,
(4) Remove bracket. .:’
,

INSTALLATION 11301620015

(1) Install bracket.

(2) Install generator brace.
(3) Install generator.
(4) Install drive belt.
(5) Loosen the generator pivot nut.
(6) Loosen the lock nut.

(7) Turn the adjusting screw to adjust the belt tension to

the standard value.
NOTE
When installing a new belt, apply 310 N (70 Ibs.) of tension
for 5 minutes or more, and then apply the final tension.
Standard value:
Used belt 400-490 N (90-110 tbs.)
New belt 490-712 N (110-160 Ibs.)
(8) Tighten the generator pivot nut.
Tightening torque: 54 Nm (39 ft.lbs.)
(9) Tighten the lock nut.
Tightening torque: 61 ,Nm (44 ft.lbs.)
,, :
. :

, _‘.,‘.
,

._ I 1.

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 ‘ I5
IlD-12 ENGINE OVERHAUL <2,OL (420A)> - lgnitibn Syktem

Ignition coil p
IGNITION SYSTEM 11301840018

I Dack fasteners
REMOVAL
The electronic ignition coil pack attaches to the cylinder head
cover.
(1) Disconnect electrical connector from coil pack.
(2) Remove coil pack mounting nuts.
(3) Remove coil.

(4) Remove spark plug cables.

(5) ‘Remove the spark plug using a quality socket with ‘a

rubber or foam insert.
(6) Inspect the spark plug condition.. Refer to Spark Plug
Condition in this section. ‘,
.\
*
’ ,

(7) Remove camshaft position sensor mounting screws on

the rear of the cylinder head.
Remove sensor.

cylinder 1

r \ -7 CENOOOZ 1

Rear of (8) Loosen screw attaching target magnet to rear of camshaft.

cvlinder

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ENGINE OVERHAUL <2.0L (420A)> - Ignition System

,(Q) Remove crankshaft position sensor mounting screw. Re-

move sensor

‘-.
_, ‘.
f.
,’
‘.*

__
:.
,_s-

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110-14 ENGINE OVERHAUL <2.0L (420A)s y lgnitjon ‘S&k
.
INSTALLATION lpllpooll

(1) Install crankshaft position sensor. ., “L

_/ -’ : I Target (2) The target magnet has locating dowels that fit into off-set
machined locating holes in end of the camshaft. install
target magnet in end of camshaft. Tighten mounting
screw to 3 Nm (2.2 ftlbs.) torque.
(3) Install camshaft position sensor. Tighten sensor mounting
screws to 9 Nm (6.5 ftlbs.) torque.
-T
ohs&
alignment
w
9-I2<+2%+&

(4) To avoid cross threading, start the spark plug into the
cylinder head by hand.
(5) Tighten spark plugs to 28 Nm (20 ftlbs.) torque.
(6) Install spark plug insulators over spark plugs. Ensure
the top of the spark plug insulator seals the upper end
of the spark plug tube.

(7) Install ignition coil pack.

Connect spark plug cables to coil pack.
The coil pack towers are numbered with the cylinder
identification.

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 ENGINE OVERHAUL <2.0L (420A)> - Ignition System ll~D46
INSPECTION
SPARK PLUG CABLE
(1) Rkistance must be between 3,000 to 12,000 ohms per
foot of cable. Replace any cable not within tolerance.

IGNITION COIL
(1) Measure the primary rkistance of each &ii. ‘At the coil,
connect an ohmmeter between the 6 + ,pirr and the pin
corresponding to the cylindW6 in qudstidn. Resistance
on the primary side of each’ coil stiould .k$ 0.51 -OB!
ohm. Replace the coil if resistance
.* is n~~wlthln tcWrark6.

Check secondary (2) Remove ignition cables from the secondaj towers of’
resistance across
the coil. Measure the secondary re$st&nc& of the coil
between the towers of each individual coil. ,SBkondary
resistance should be 11,500-l 3&&I ohms. Replace the
coil if resistance is not within tolerance.

,1.
:v,

CENOO94

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llD-16 E N G I N E O V E R H A U L <2.0L (420A)> - Timing Belt’ ., ,, j i

TIMING BELT 11301860021

REMOVAL
Caution
Camshaft or crankshaft should not be rotate after timing
belt is removed. Damage to valve components may occur.
Always align timing marks before removing timlng belt.

(1) Remove crankshaft damper bolt. Remove damper using

Special Tool MB995055 and insert MB995057 or equiva-
lent.
Special
tool
MB9950

CEN0130 1

(2) Remove engine mount bracket.

(3) Remove front half of timing belt cover.

CENOOO8

(4) Align timing marks. Loosen timing belt tensioner screws

and remove timing belt.
(5) Remove tensioner pulley
(6) Remove timing belt tensioner.
(7) Remove tensioner arm bracket.
(8) Remove idler pulley.
Tensioner A
pulley
Timing belt
tensioner

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 ENGINE OVERHAUL <2.0L (420A)> - Timid Belt

Tensioner Bench vise (9) When tensioner is removed from the,enginei it is necessary
to compress the plunger into the tensioner body.
(10)Place the tensioner into a vise and slowly compress the
plunger.
LOC ‘,
pin Caution
Index the tensioner In the vi& the samp hay it Is
installed on the engine. This is to ens& proper
pin orientation when tensloner ‘is installed on the
engine.

(ll)When plunger is compressed into the tensioner body

install a pin through the body and plunger to retatn plunger
in place until tensioner is installed. 1. .,
,‘F

(12)Hold camshaft sprocket with Special Tools MB990767

and MD998719 while removing bolt.
(13) Remove support bracket.

/’
,-

(14)Remove rear timing belt cover fasteners.

Remove cover. I
‘I
_a ’

(15)Remove camshaft seal.

I,
: .y
I
_. :
1-e. ’ _‘. .

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MD-18 ENGINE OVERHAUL <2.0L (42bA)> - Timing Belt .I _ ,,

INSTALLATION .’ 11301870017

(1) Install camshaft seal into cylinder head using Special

Tool MD998713 until flush with the head.
NOTE
Shaft seal lip surface must be free of varnish, cfrh’or
nicks. Polish with 400 grit paper if necessary.
: 2

(2) Install rear timing belt cover.

Tighten fasteners to 9.6 Nm (6.9 ftlbs.).
(3) Install support bracket.

(4) Install camshaft sprockets and tighten attaching ,bofts to,

101 Nm (73 ftlbs.).
(5) Install idler pulley.
(6) Install tensioner arm bracket.
(7) Install timing belt tensioner. ,
(8) Install tensioner pulley.
1 I’ ,

_..

(9) Set crankshaft sprocket to TDC by aligning the sprocket

with the arrow on the oil pump housing ,”
1’ 1 ,
‘I

(lO)Set camshafts timing marks together by aligning .notches

on sprockets.
(ll)Move crankshaft to l/2 notch before TDC. .__,
_ . P-

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 ENGINE OVERHAUL <2.0L (420A)> - Timing Belt
(12)lnstall timtng belt. Starting at the crankshaft, go around
Tensioner the water pump sprocket, ‘idler pulley, camshaftsprockets
Pulley ICL and then around the tensioner pulley. ,:
this direction (13)Move crankshaft sprocket to TDC’ to..take up belt slack.
4
Install tensioner to block but do not tighten fasteners.
(14)Using a torque wrench on the tensioner ~ pulley, apply
into the 28 Nm (20 ftlbs.) of torque to tensioner.
tensioner 2 /

(15)With torque being applied to the tensioner pulley move

the tensioner up against the tensioner pulley bracket,and
tighten fasteners to 31 Nm (22 ft.tbs.). ‘.
(16)Pull tensioner plunger pin, Pretension is , correct when
pin can be removed and installed.
(17)Rotate crankshaft 2 revolutions and check the alignment
of the timing marks.

Crankshaft
It TDC
Install belt in
‘this directior
I I II I,
here
CENOOW

- Timing belt (18)lnstall front timing belt cover.

-75L!l. ’ . inspection
ver
i&fastener

(19)Valve Timing Check; (timing belt cover installed), remove

the inspection cover on timing belt cover. With number
one cylinder at TDC, the timing marks on the camshaft
sprocket should be aligned together. If marks are not
aligned correctly, perform procedure again.

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11 D-20 ENGINE OVERHAUL <2.0L (420Ak - Timinn Belt

(20)lnstall engine mount br&keii

Tighten bolts to 41 Nm (30 ftlbs.).

w CENODO7

M12-1.75x15Ommbolt, (2l)lnstall crankshaft damper using MB995035 ;

washer thrust bearing Using Special Tools MB990767 and MD998719 to hold
from special tool kit
ME995035 damper, tighten crankshaft bolt to 62 Nm (45 ft.lbs.).

CENOWO

‘: “,!< ,

\ :, 1 “, ,. .,,

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 ENGINE OVERHAUL <2.0L (420A)> - Cooling System Compdnents Wl D-21

COOLING SYSTEM COMPONENTS

11ao188w10

REMOVAL
(1) Remove water pump attaching screws to engine.

(2) Remove ,oil level gauge.

(3) Remove exhaust manifold cover. 7 ’
(4) Remove water hose.
(5) Remove water pipe.
(6) Remove O-ring.
1

(7) Remove thermostat housing bolts and housing.

(8) Remove thermostat, discard gasket and clean both gasket
sealing surfaces.

Thermostat
Thermostat Gasket CEN0023

(9) Remove engine coolant temperature sensor.

(10) Remove therm0 switch.

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 11 D-22 ENGINE OVERHAUL <2.0L (420A)> - Cooling System &mpohehs
INSTAiLATlON 113019ooo1~

(1) Install therm0 switch.

(2) Install engine coolant temperature,,sensor. lighten sensor
to 7 Nm (5 ftlbs.) torque.

Pressure cap (3) Place a new gasket (dipped in clean water) on water
Overflow
nipple \ box surface, center thermostat in water bqx qn gasket.
I
Place housing over gasket and thermostat; making sure
thermostat is in the thermostat housing. Bolt housing
to water box. Tighten bolts to 22 Nm (16 ft.lbs.).

(4) Install O-ring.

(5) Install water pipe.
(6) Install water hose.
(7) Install exhaust manifold cover:
(8) Install oil level gauge.

(9) Install new O-ring gasket in water pump body O-ring

groove.
Caution
Impeller Make sure O-ring is properly seated in water pump
groove before tightening screws. An improperly
located O-ring may cause damage to the O-ring and
O-ring cause a coolant leak.
(1O)Assemble pump body to block and tighten screws to 12
Nm (9 ftlbs.)
CENO024 (ll)Rotate pump by hand to check for freedom of movement.

INSPECTION iiaomwoia
Replace water pump body assembly if it has any of these
defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by coolant
traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the engine block.
(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.
I I
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 ENGINE OVERHAUL <2.0L (420A)> - Fuel and Emissioil Contiol’ Rartrr 44 DA23

Intake manifold FUEL AND EMISSION CONTROL PARTS

11661916616

REMOVAL
(1) Remove screws attaching EGR tube to intake manifold.

(2) Remove EGR valve mounting screws. Remove EGR

valve and transducer.

(3) Disconnect purge hose from throttle. body.

(4) Remove throttle body mounting bolts. RemoveI. throffle
body.
(5) Remove gaskets. Clean gasket matfng surfaces.
(6) Release fuel system pressure. Refer to Fuel. system
Pressure Release procedure in this section..‘,

(7) Remove fuel rail mounting screws. Access screws through

the space between the intake manifold plenum runners.

(8) Lift rail off of intake manifold. Cover the fuel injector
Retainer Fuel openings in the intake manifold.
(9) Remove fuel injector retainer.
(1O)Pull injector out of fuel rail. Replace fuel injector O-rings.
11 D-24 ENGINE, OVERHAUL <2.0L (42OA)> - Fuel and Emission Control,, ks *. ),

INSTALLATION 11ao1920019

(1) Apply a light coating of clean engine,, oil to the upper

O-ring.
(2) Install injector in cup on fuel iail.
(3) Install retaining clip. ‘8
(4) Apply a light coating of clean engine oil to ‘the -O-ring
on the nozzle end of each injectar. “’
(5) Insert fuel injector nozzle into openings in intake manifold.
Seat the injectors in place. Tighten,‘fuel rail mount?ng,
screws.
_.
(6) Connect fuel supply tube to fuel rail.
(7) Install throttle body and new gasket on intake manifold.
Tighten mounting bolts. ’

(8) Connect purge hose nipple on throttle body.

(9) Loosely install EGR valve with a new. gasket. Install
new gasket between EGR tube and EGR valve:
(lO)Finger tighten EGR tube fasteners.
(ll)Tighten EGR valve mounting screws to 22 Nm (16 ftlbs.)

(12)$%zn EGR tube fasteners to 11 firn &t.lbs.), torque.

(13)Connect vacuum supply tube to solenoid.;

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 ENGINE OVERHAUL <2.0L (42OA)> - Intake, Manifold 14 D4S

INTAKE MANIFOLD ” I),

REMOVAL ‘8’
(1) Remove intake air temperature sensor.

(2) Remove manifold absolute pressure (MAP) sensor mount-

ing screws.
(3) Remove manifold absolute pressure (MAP) sensor.

EGR tube (4) Remove intake manifold stay.

(5) Remove EGR tube fasteners from the intake+“manif&d
and valve. Remove tube from engine.
:(6) Remove vacuum hose and electrical connection from in-
take manifold.
(7) Remove attaching screwsfrom engine and remove intake
manifold from engine.
I .

,.. ’

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11 D-26 ENGINE OVERHAUL <2.0L (420A)s - Hake Maidfold

EGR tube INSTALLATION 11661966616

(1) Install new manifold gasket. DO NOT APPLY SEALER.

(2) Set manifold in place. Tighten retaining fasteners, starting
at center and progressing outward in both directions to
23 Nm (17 ftlbs.). Repeat this procedure until all fasteners
are at specified torque.

(3) Install vacuum hose and electrical’ connection from intake

manifold. ., .
(4) Install new EGR tube gaskets at the~imake manifold:and
valve. ,j, ,
(5) Install EGR tube and tighten fasteners to 8 ,f$n (6 ‘ft.&). ’
(6) Install intake manifold stay. . &., ,‘:
*; * ‘.ii.
.* I

(7) Insert sensor into .intake manifold while making surenot

to damage O-ring seals. ,‘. _, _.
(8) Tighten mounting screws to 2 Nm (1~4 ft.lbs,) torque.

:I ., ,; ,’
)_ i
”

(9) Install manifold air temperature sensor. Tighten sensor

to 7 Nm (5 ftlbs.) torque.

CLEANING AND INSPECTION .11361646616

(1) Discard gasket and clean gasket surfaces of manifold.

(2) Test manifold gasket surfaces for flatness with straight
edge. Surface must be flat within 0.15 mm per 300 mm
of manifold length.
(3) Inspect manifold for cracks or distortion. Replace manifold
if necessary.

( TSB Revision
ENGINE OVERHAUL <2.0L (42OA)> - Exhaust Manifotd “ ’ w&27
7

EXHAUST MANIFOLD 6 “1 ~ ,so~-o(lool~~.

.,I
REMOVAL ; ‘.
(1) Remove oil level gauge.
(2) Remove exhaust manifold. heat shield, i
(3) Remove 8 exhaust manifold retaining ‘&tenets and re-;
move exhaust manifold.

CENO032

INSTALLATtON ;. I, ” 1j~1esoO17-

(1) Install new manifold gasket. DO NOT APPLY-SEALER.

(2) Set exhaust manifold in place: Tighten retarnrng nuts
and bolt, starting at center and progreeslng ,outWard- in
both directions to 23 Nrn, (‘17 ft.lbs.) torque.” Repeat this
procedure until all fasteners are at specified tOrque.
(3) Install exhaust manifold heat shield, , ;, ,.
(4) Install oil level gauge. ‘~.‘,’
,* 5. _’ 5,

CENO032

CLEANING AND INSPECTION 11ao1970014

(1) Discard gasket and clean all gasket surfaces of manifolds

and cylinder head.
(2) Test manifold gasket surfaces for flatness with straight
edge. Surface must be flat within 0.15 mm per 300 mm
(.006 in. per foot) of manifold length.
(3) Inspect manifolds for cracks or distortion. Replace man-
ifold if necessary.

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11 D-28 ENGtNE OVERHAUL <2.0L (42OA)> - Camshaft and Cam ‘F&lower

CAMSHAFT AND CAM FOLLOWER

11301990010

REMOVAL
(1) Remove the cylinder head cover fasteners. *
(2) Remove cylinder head cover from cylinder head.
i .,

I
,.
askets CENOO33 .’ -_p, r* , :v i;4, ,
,; 4
(3) Bearing caps are identified for loca&i. T?emo& the
outside bearing caps first.
.“:

CENO034
.
-
(4) Loosen the camshaft bearing cap attaching fasteners
in sequence shown in one camshaft at a time.
Caution
Camshafts are not interchangeable. The exhaust cam
number 6 bearing journal -Is wider. ‘: ’ k.7
,.’
i.1.’ .‘.<
fl
“.‘ ‘. :.
ice ”
: >.1;.’ ,
(5) Identify the camshaffs before removing fromthe he’kd.
The cams are not interchangeable.’
(6) Remove cam follower assemblies ,from. cylinder head.
Keep the cam followers in the order they have been
removed from the head for reassemtjly.-’
(7) Mark hydraulic lash adjusters for reassembly in their orjgi-
nal positions. *
Lash adjusters are serviced as an assembly.

CLEANING J13o2aowl9

Before installation, clean cylinder head and cover mating sur-

faces. Make certain the rails are flat.

.
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 ENGINE OVERHAUL <2.0L (42OA)> - Camshaft and Cam Followk 11’0-29

INSTALLATION “.‘ 115o2o2oo15

(1) Install hydraulic lash adjuster assembl making. sure that

adjusters are at least ,paitially fir/t of oir:‘.‘fhis is jndicated
by little or no plunger travel *when the lash adjuster is
depressed. $5 ’ >’ Y.<
I ,.:?. . ‘W (.,.,‘-;, ; :i
,. *-, I ..^
.::
/ .’ ‘. ,, _ * ;‘. ,,*.: XJk:

(2) Lubricate with clean oil and install cam follower assemblies
in their original position on the hydraulic adjuster and
valve stem.

Caution
Piston should NOT be at top dead center when lnstal-
ling the camshaft.
(3) Lubricate bearing journals and cams with clean oil and
install the camshafts. Install right and left camshaft bearing
caps No. 2 thru No. 5 and right No.6. Tighten M6 fasteners
to 12 Nm (9 ftlbs.) in sequence shown in the figure.
I

(4) Apply Loctite 51817 to No. 1 and No. 6 bearing caps.

Front bearing cap (No. 1 cap) Install bearing caps and tighten M8 fasteners to 28 Nm
(21 ftlbs.).
(5) Bearing end caps must be installed before seals can
be installed.
(6) Install timing belt, sprockets and timing covers. Refer
diameter bead of to “Timing belt”.
Loctite 51817
Caution
Do not allow oil or solvents to contact the timing
Left rear bearing cap (No.6 cap) CENot)41 belt as they can deteriorate the rubber and cause
tooth skipping.
(7) Install new cylinder head cover gaskets.
(8) Apply Loctite 18718 at the camshaft cap corners and
at the top edge of the l/2 round seal.

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11 D-30 ENGINE OVERHAUL <2.0L (42OA)> -. Cayhafit’&nd C&k Foll@&
(9) Install cylinder head cover assembly to head and tighten
fasteners in sequence shown in the figure. Using the
3 step torque method:
Step 1 Tighten all fasteners to 4.5 Nm (3.3 ft.lbs.)
Step 2 Tighten all fasteners to 9.0 Nm (6.5 ft.lbs.)
Step 3 Tighten all fasteners to 12 Nm (9 ft.lbs.)

Spark plug well gaskets CENMJ~~

,I

. ,.

i I.
’

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ENGINE OVERHAUL <2.0L (420A)> - Camshaft and Cam Follower qlDm34
INSPECTION 11202010012

CAMSHAFT
(1) Inspect camshaft bearing journals for damage and bind-
ing.
I If journals are binding, also check the cylinder head bear-
III Ha ing surface for damage, and check the camshaft bearing
oil feed holes in the cylinder head for clogging.
(2) Check the cam surface for abnormal wear and damage.
Replace if defective. Also measure the cam height and
CENOO36 replace if out of limit.
Standard value: 0.0254 mm (.OfIl in.) I
Limit: 0.254 mm (.Ol in.) ” : , _,, :
To measure cam lobe Wear< measure lobe diameter in
two places at the largest diameter @ver thq no!S;er).*0 Take
first reading with micrometer in~unwo:rn area ‘at the edge
of the lobe. Take second reading in fh6 worn a&a where
cam follower contacts the lobe: Subtractsecx$rd ‘f6qding
from the first. The differen.ce is ‘the,,cam
1I Idbe ‘wear.
_I

CAM FOL&OWER
(1) Inspect the cam follower assembly for wear ~rq damage.
h adjuster Replace as necessary. %
ket
I’

Roller
CENOO37 1

CAMSHAFT END PLAY

(1) Oil. camshaft journals and install camshaft without cam
follower assemblies. Install rear cam caps and tighten
screws to specified torque.
(2) Using a suitable tool, move camshaft as far rearward
as it will go.

(3) Zero dial indicator.

(4) Move camshaft as far forward as it will go.
End play standard value: 0.15 mm (.006 in.)

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11 D-32 ENGINE OVERHAUL <2.0L (42OA)> - Cylifid&r &ad., a’ti .“V&@ ‘I

C Y L I N D E R HEAD :.:
A N D V&LtiE
- ‘3.
1;30#)30015
(2 i
REMOVAL
(1) Remove cylinder head bolts. ” ” ‘I i
,..l
_ :

(2) With cylinder head removed, compress valve springs using

Special Tool MD998772 or equivalent.

(3)’ Remove’valve retaining locks, valve siring retainers and

valve- spring. ,-.’ ,
(4) Remove valve stem seal/valve spring seat ‘b&using Spe-
cial Tool MB995037 or equival,ent.‘:’ Y
(5) Before removing valves, remove gny but& from valve
stem lock grooves to prevent damage to the valve guides.
Identify valves to’ insure installation.‘ln original location.

CLEANING 11302o4oo11

CYLINDER HEAD
Caution
Be careful not to gouge or scratch the aluminum head
sealing surface.
(1) Remove all gasket material from cylinder head and block.

VALVE ASSEMBLY , i
(1) Clean all valve guides, valves and valve spring assemblies
thoroughly with suitable cleantng solutionbefore ., j reassem-
bling. : , i-J s
.e.‘r,
,,‘Il’lj $ i’, ,..b,
*: .a ;,

, . . :I

:I 1.

I
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ENGINE OVERHAUL <2.0L (420A)> - Cylinder HFad and Valve 11p33
INSTALLATION i13020soo14

(1) Coat valve stems with clean engine oil and insertthe,m
in cylinder head:
(2) If valves or seats have been reground,! chedi valve tip
Valve retaining locks height (A).
Make sure of measurements from cylinder head surface
c, i 3,.
to the top of valve stem.
(3) Install valve seal/spring seat assembly over valve guides
- Valve seal and on all valve stems. Ensure that’the garter springis intact
around the top of the rubber seal. Install valve springs,
valve retainers.

CENOOSO

(4) Compress valve springs with a valve spring compressor.

Install locks and release tool.

(5) Before installing the bolts, the threads should be oiled

with clean engine oil.

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11 D-34 ENGINE OVERHAUL <2.0L (42(h)> - Cylinder Head’and Ifake

(6) Tighten the cylinder head bolts in the sequence shown

in the figure.
Using the 4 step torque turn method, tighten according
to the following values:
Step 1
Tighten center fasteners 1 thru 6 to 33 Nm (24
ftlbs.), then outer fasteners 7 thru 10 to 26 Nm
(20 fklbs.) .I
Step 2
l Location of 110 mm (4.3 Tighten center fasteners f thru 6, to 67. Nm (46
, ‘.. ‘IO to 28 Nm
ftlbs.), then outer fasteners’ 7 ‘tbru
(20 ftlbs.). ..
Step 3
Tighten center fasteners 1 thru 6 to 67:km (46
ft.lbs.), then outer fasteners 7 thru ‘10 to %I ‘Nm
(20 ftlbs.). ‘.
Step 4
Turn all fasteners 1 thru 10 l/4 turn (90 degrees).
Do not use a torque wrench for this step.

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 11Da
ENGINE OVERHAUL <2.0L (42OA)> - Cylinder Head atid;~Valve /,

INSPECTION 11390790119

CYLINDER HEAD
(1) Check the cylinder head gasket surface for flatness by
using a straightedge and feeler gauge.
Limit: 0.1 mm (004 in.)

VALVE
(1) Clean valves thoroughly and discard burned, warped and
cracked valves.
(2) Measure valve stems for wear.
(3) If valve stems are worn more than 0.05 mm (.002 in.),
replace valve.
Standard value:
Intake 5.934-5.952 mm (.233 -.234 in.)
Exhaust 5.906-5.924 mm (.233-.233 In.)

VALVE GUIDES
(1) Remove carbon and varnish deposits from inside of valve
guides with a reliable guide cleaner.

(2) Using a small hole gauge and a #micrometer; measure

valve guides in 3 places top, middle-and bottom. Replace
Top Cut away view guides if they are not within specification. a ‘,_
of valve guide Standard value:
measurement
Middle locations Intake 0.046-0.066 mm (.0019 -.6026 In.) ”
Exhaust 0.074-0.094 mm (.0029-.0037 in.)
Bottom
Limit:
Intake 0.076 mm (003 in.)
Exhaust 0.101 mm (004 in.)
CEN0045 1

TESTING VALVE SPRINGS

(1) Whenever valves have been removed for inspection, re-
conditioning or replacement, valve springs should be
tested. As an example, the compression length of the
Tester valve spring to be tested is 33.34 mm (1.313 in.).
sprin Turn table of Tool until surface is in line with the 33.34
mm (1.313 in.) mark on the threaded stud and the zero
mark on the front. Place spring over stud on the table
and lift compressing lever to set tone device. Pull on
torque wrench until ping is heard. Take reading on torque

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11 D-36 E N G I N E O V E R H A U L <2.0L (420A)> - Cylindi?r Head and Valve’ ,_

wrench at this instant. Multiply this reading by two. This

will give the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjustments. :
Refer to specifications to obtain specified hei@ and allow-
able tensions. Discard the springs that dq *t ket spxifi-
,* <j A
cations.
Standard value:
Free length 46 mm (1.611 in.) ” , s
Spring tension I
V a l v e closed 246-270 t&6.0 m i n
(SO-SO Ibsll.496 i n . )
Valve open 459-611 N/29.3 mm
(123-137 lbsJ1.153 in.)
(2) inspect each valve spring for squareness with a steel
square and surface plate, test springs from both ends.
If the spring is more than 1.5 mm (.06 in.) out of square,
install a new spring.

REFACING VALVES AND VALVE SEATS

(1) The intake and exhaust valve seats and valve face have
a 45 degree angle.

.”
(2) Inspect the remaining margin after the valves are refaced.
Exhaust valve I Exhaust valves with less than 0.95 mm (.0037 in.) margin
and intake valves with less than 1.05 mm (AI413 in.)
m.argin should be discarded and replaced.
Margin ,;
I ,‘,
)’
‘,

Intake valve

^
Standard value:
Facti Angle
Intake and Exhaust 45-45.5”
Head Diameter
Intake 34.67-34.93 mm (1.364-l .375’ in.) “*
Exhaust 30.37-30.63 mm jl .i q5~1.205 tn.)

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 Length< (Overall)
Intake 111.49-111.99 mm (4.389-4.499 in.)
Exhaust 109.59-110.09 mm (4.314-4.334 in.)
Stem Diameter
Intake 5.934-5.952 mm (.233-.234 in.)
Exhaust 5.906-5.924 mm (.233-.233 in.)
Valve Margin
Intake 1.285-1.615 mm (.050-.063 in.)
Exhaust 0.985-1.315 mm (.038-.051 in.)

(3) When refacing valve seats, it is important that the correct

size valve guide pilot be used for reseating “tb^nt?f,; A
true and complete surface must fbe ,obtained.‘; ‘( “..
,. /

(4). Measure the concentricity of valve seat using a valve

seat dial indicator. Circular runout should not exceed.
Limit:
0.05 mm (.002 in.) Indicator reading.

(5) Inspect the valve seat with Prussian blue to determine

where the valve contacts the seat.
To do this, coat valve face LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light pressure.
If the blue is transferred to the center of valve face, contact
is satisfactory. If the blue is transferred to top edge of
the valve face, lower valve seat with a 15 degree stone.
A-Seat width (intake and exhaust 0.9 to 1.3 mm If the blue is transferred to the bottom edge of valve
(.035 to ,051 in.)
S-Face angle (intake & exhaust: 45’-45.5”) face raise valve seat with a 65 degree stone.
C-Seat angle (intake 8 exhaust: 44.5’-45” )
D-Seat contact area
CENOO48

Intake valve seat diameter

34.50 mm (1.358 in.)
Exhaust valve seat diameter
29.50 mm (1.161 in.)
Valve seats which are worn or burned can be reworked
if correct angle and seat width are maintained. Otherwise,
cylinder head must be replaced.

1 TSB Revision ’ ‘I
11 D-38 ENGINE OVERHAUL <2.0L (420A)> - Cylinder Head anti V&We

(6) W.hen seat is properly positioned, the width of intake

and exhaust seats should be 0.9 to 1.3 mm (.035 to
.051 in.).

(7) Check valve tip to spring seat dimensions A after grinding

the valve seats or faces. Grind valve tip until dimesion
A is equal to 47.99 mm (1.889 in.) for exhaust valve
and 48.04 mm (1.891 in.) for intake valve over spring
seat when installed in the head.
The valve tip chamfer may need to be reground to prevent
seal damage when the valve is installed.

CENO049

(8) Check, the valve spring installed height B after refacing

the valve and seat. Make sure measurements are taken
from top of spring seat to the bottom surface of spring
retainer.
If .height is greater than 38.00 mm (1.496 in.), install a
0.762 mm (.030 in.) spacer in head counterbore under
the valve spring seat to bring spring height back within
specification.

r,, ./. I:, I

,”

1 TSB Revision I
 ENGINE OVERHAUL <2.0L (42OA)> - Oil Pan dnd ‘qil Pump q$@@J
,

REMOVAL
,, ,- ‘9’
(1) Remove flywheel or drive plate: .I ,~
(2) Remove rear plate. :.,
(3) ‘Remove oil filter. S ” )
(4) Remove adapter. ,‘,I :;
,. - :,
.” 4. .: . .

(5) Drain engine oil and remove oil pan.

(6) Clean oil pan and all gasket surfaces.
(7) Remove oil pick-up tube.

.:
(8) Remove crankshaft sprcckef using ?becial Tool,
MB995027.
Caution :.
Do not nick shaft seal surface or seal bore:

Special tool MB995027

(9) Use Tool MB995020 to remove front, cranksha&$i’ seal:

,Be careful not damage the se~~~surface ofoover. .i;,, ;
I,., ,‘.“!?’ ‘)’ .,

v
CENOO54

(lO)Remove oil pump.

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11 D-40 ENGINE OVERHAUL <2.0L (420A)> - Oil Pan and Oil’ Puthp.

INSTALLATtON 11302o7Do10

(1) Apply Loctite 51817 to oil pump as shown in the figure.

Install oil-ring into the counter bore on the oil pump body
discharge passage.
(2) install oil pump slowly onto crankshaft until seated to
engine ‘block. Tighten fasteners to 23 Nm (17 ftlbs.).

CENW55

(3) Install new seal by using Tool MB995022.

-’
CENtlO

M12-1.75x16Ommbolt, (4) Place seal into opening with seal spring toward the inside
.of engine. Install seal until flush with cover. ’
(5) Install crankshaft sprocket using M12-1.75 x I.50 .mm
bolt, washer and thrust bearing, from Special ‘Tool Kii
MB995035 and Tool M.B995&%. .L I_
.I :
: I
II_ ,
~ *il ..‘, _I
.5.’ .
0057

(6) Install oil pick-up tube.

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 $+a;$q
E N G I N E O V E R H A U L <2.0L (42OA)> - Oil ‘Pan and Oil Pump ,,, ,,,,

(7) Apply Loctite 18716 or equivalent at the oil’pumfl to engine

bed plate parting line.

CENOO58

(8) Install the oil pan gasket to the bed. plate. -Use Mopar
Silicone Rubber Adhesive Sealant
.< or equivalent to hold
in place.
(9) Install oil pan and tighten the screws to 12 Nm (9 ftlbs.).

Locating
(lO)Ensure O-ring is in the groove on adapter. Align roll
pin into engine block and tighten assembly to 55 Nm
I (40 ftlbs.).

adapter

CEN0060

Caution
When servicing the oil filter avoid deforming the filter
can by installing the remove/install tool band strap
against the can-to-base lockseam. The lockseam join-
Oilf ing the can to the base is reinforced by the base
plate.

Locate wrench band”+

at base of filter

(11)Lubricate new filter gasket and install it on filter.

(12)Check filter mounting surface. The surface must be
smooth, flat and free of debris or old pieces of rubber.
(13)Screw filter on until gasket contacts base. Tighten to
3/4 turn or Torque to 21 Nm (15 ftlbs.).
(14)lnstall rear plate.
(15)lnstall flywheel or drive plate.

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11 D-42 ENGINE OVERHAUL <2.0L (420A)> -’ Oil Pump

F!Finer.-@-- Gasket
OIL PUMP - 11ao2oeoo18
DISASSEMBLY ‘,
‘,
Sprin (1) To remove the relief valve,’ proceed as folfqws:
Re (a) Remove the threaded plug and gasket from the oil
val w-v. ,’ I
Caution
Install oil pump pressure relief valve as shown
in the figure, or serious damage may occur.
(b) Remove spring and relief valve.
(2) Remove oil pump cover screws, and lift off cover. I
Oil pump body (3) Remove pump rotors.

Outer
rotoy L>
\

KY-- Oil pump cover

CENOO63

REASSEMBLY 11302o9oo16’

(1) Assemble pump, using new parts as required. j

Install the inner rotor with chamfer. fac!ng t-he cast, iron,
oil pump cover. ,. i
-.

(2) Tighten cover screws to 12 Nm (9 ff.lbs.).

(3) Install relief valve, spring, gasket anl cap. Tighten cap
to 54 Nm (39 ftlbs.) i,,t ,- *
(4) Prime oil pump before installation by filling .rotqr cavity
with engine oil. zi

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ENGINE OVERHAUL <2.0L (42OA)> - Oil’Pump
INSPECTION ~MO223OOli

(1) Wash all parts in a suitable solvent and inspect%arefulfy’

for damage or wear.
(2) Mating surface of the oil pump should be smooth. Replace
pump cover if scratched or ,‘grooved. ,’ dP
’
i,

(3) Lay a straightedge across the pump cover surface. If’

a feeler gauge of 0.076 mm (.003 ‘in.) or more can be
inserted between cover and straightedge, cover ,should
i’
be replaced.
Limit: 0.076 mm (.003 in,)

(4.) Measure thickness and diameter of outer rotor. If outer

rotor thickness measures 7.64 mm (.301 in.) or less, or
if the diameter is 79.95 mm (3.148 in.) or less, replace
outer rotor.

(5) If inner rotor measures limit or less, replace inner rotor.

/’
Limit: 7.64 mm (.301 in.)

CENOO&

(6) Slide outer rotor into pump housing, press to one side
with fingers and measure clearance between rotor and
housing. If measurement exceeds the limit, replace hous-
ing only if outer rotor is in specification.
Limit: 0.39 mm (.015 in.)
1 l,D-44 E N G I N E OVERHAUL <2.0L (42OA)> -‘Oil Piim#

(7) Install inner rotor into pump housing. If clearance between

inner and outer rotors exceeds the limit, replace both
rotors.
Feeler 2 Limit: 0.203 mm (.008 in.)
gauge

0 .J
48
Outer
rotor
0

(8) Place a straightedge across the face of-the pump houstng,

between bolt holes. ff a feeler gaugeof 0.102 mm (.OO41
in.) or more can be inserted ‘betweqn.roQrs and the,
straightedge, replace pump ,assembly.
,, _! L’
Limit: 0.102 mm (.004 in.)-‘.
, a’

(9) Inspect oil pressure relief valve plunger for scoring-and.

free operation in its bore. Small marks may. be removed,
with 400-grit wet or dry sandpaper. ,. ,.,
:, 1,

'j
. ., i" -_.

::iner- Gasket
I
(10)The relief valve spring has a free length of-approxknatefy’
60.7 mm (2.39 in.). It should test between 84 -and 64 N
when compressed to 40.5 mm (1.60 in.). , Rep&$! spring
that fails to meet specifications. ,: ’
‘.,
‘I ., . ,,..*-?a” ., I _.- 1
,i ;’ 1
; >,

(11 )If oil pressure is 10% and pump is within specifici@ns,

inspect for worn engine bearings, or other ,reasons for
oil pressure loss. .>“
,I’’ 8’
b 2 ~~ &
I - ,_
.:c ” . - . .; ?,
‘1 “‘_: , ~, > ‘.; .J ,
’ __ J&L . &.. ;i.: 1
* ,:, ru’l,” ;” I’- ‘C S? ,
*,.:
1: c
/ 1. ..:- ,_., ,i
._, ’
,’ /. _:
I I - .,
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 Piston, C\onnecting Rod
ENGINE OVERblAUL <2.0L (420A)> - and Cylinder Block ‘*
Rear 1 Engine block PISTON, CONNECTING ROD ;AN”D
crankshaft seal
metal case Engine
I CYLINDER BLOCK ., 1130211aoa
crankshaft seal

REMOVAL
(1) insert a 3/16 flat bladed ‘screwdriver between the dust
lip and the metal case of the .crankshaft seal.
Angle the screwdriver through the dust lip against metal
Rear
case of the seal. Pry out seal. ,, ,*
crankshaft seal Caution
Scr&driver dust lip CENOl31
Do not permit the sCrewdriver blade tb contact
crankshaft seal surface. Contact of the screwdriver
blade against crankshaft edge (chamfer) is permitted.
(2) Remove top ridge of cylinder bores with a reliable ridge
reamer before removing pistons from cylinder block.
Be sure to keep tops of pistons covered during this opera-
tion. Mark piston with matching cylinder number.

(3) Ensure connecting rods and connecting rod caps match

and proper set for the cylinder number. Identify them
if necessary.

I CENOO71
I

(4) Pistons and connecting rods must be removed from top

of cylinder block. Rotate crankshaft so that each connect-
ing rod is centered in cylinder bore.

CENOO72 1

(5) Remove connecting rod cap bolts. Push each piston

and rod assembly out of cylinder bore.
Be careful not to nick crankshaft journals.
(6) After removal, install bearing cap in the connecting
orientation on the mating connecting rod.

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 Piston, Connecting Rod
11 D-46 ENGINE OVERHAUL <2.0L (420A)> - and Cylindei Blbck

) DISASSEMBLY .I ’
11202120012
.#,S
(1) Separate piston from connectin’g rod by removing piston
pin.
(2) Using a suitable ring expander,, remove ubper and inter-
mediate piston rings. ‘.
I”,..

(3) Remove the upper oil ring side rail, lower oil ring side
rail and then oil ring expander from piston.
(4) Clean ring grooves of any carbon deposits.

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 Pistoq, Connading Rod
ENGINE OVERkAUL <2.0L (420A)> - and Cylinder ‘Blo$k,.”

REASSEMBLY 11202140018

(1) Install rings with manufacturer’s I.D. mark facing up, to-
ward the top of the piston.
Caution
Install piston rings in the following order:
(a) Oil ring expander.
(b) Upper oil ring side rail.
(c) Lower oil ring side rail.
\
I I
CENOOBS
(d) No. 2 intermediate piston ring.
(e) No. 1 upper piston ring.
(2) Install the side rail by placing one end between the piston
ring groove and the expander. Hold end firmly and press
down the portion to be installed until side rail is in position.
Do not use a piston ring expander.

(3) Install upper side rail first and then the lower side rail.

(4) Install No. 2 piston ring and then No. 1 piston ring.

(5) Position piston ring end gaps as shown in the figure.

4 Front of engine

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 Piston, Connqting. FJo?
11D-48 ENGINE OVERHAUL <2.0L (420A)> - and Cylinder Blocks ,..,/. ,,, .,

(6) Position oil ring expander gap at least 45 degrees irom

the side ,rail gaps but not+ ‘on the “pistdn pin canter OJ
on the thrust direction. Staggering ri,ng ,gap,is important
for bil control. 1
a .4.; _
’

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 piston, Coqnegti qLPpd a$ji @4Q
.,_. ’ E$ck
ENGINE ,OVERkAUL <2.0L (42OA)> i.Pnd Cylihder _ ,j,

IWTALLATION 11302150028
,

(1) Before installing pistons and connecting rod assemblies

into the bore, be sure that compression ring gaps are
staggered so that neither is in line with oil ring rail gap.

(2) Before installing the ring compressor, make sure the oif
ring expander ends are butted and the rail .gaps located;
as shown in the figure.
i , \‘p”
4 Front of engine

I’,:i_.
._ ._ .

(3) Immerse the piston head and rings in clean engine oil,
slide the ring compressor, over the piston. Be sure that
position of rings does not change during this operation.

(4) The arrow should face toward the front of the engine.
Install the pistons.

CENOO72 1

(5) Rotate crankshaft so that the connecting .rod journal is

on the center of the cylinder bore. Insert rod and piston
assembly into cylinder bore and guide rod over the crank-
shaft journal.

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 Piston, Connecting f&d
llD-50 ENGINE OVERHAUL <2.0L (420A)> - and Cylitider Blodk “, _ ~ _

(6) Tap the piston down in cylinder bore, using a hammer

handle. At the same time, guide connecting rod into
position on connecting rod journal.

(7) Install connecting rod bearings selected based on !he

obtained connecting rod bearing clearanck ‘:
(Refer to CONNECTING ROD BEARING CLEARANCE.)

CENOO89

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 piqton, ConnectiTg Rod
ENGINE OVERHAUL <2.0L (420A)> - a n d Byh,nder Bltsck::

(8) Install each bolt finger tight then alternately torque each
nut to. assemble the cap properly.
(9) Tighten the bolts to 27.0 Nm PLUS l/4 turn (20 ft.lbs.
PLUS l/4 turn). Do not use a torque wrench for last
step.

(lO)Using a feeler gauge, check connecting rod’ side clear-’

ante.
Standard value: 0.13-0.38 mm (.005-.015 in.)
Limit 0.37 mm (.015 in.)

Caution
If burr’or scratch is present on the c&k&& edge
(chamfer), cleanup with 400 grit sar@ paper to prevent
seal damage during’ inritaUqtion .of I new’ ~s&tl?
1: *-
NOTE _
When installing seal, no lube on seal is needed. ~ .L ,‘,
(11) Place Special Tool MB995059 on crankshaft. This is a i
pilot tool with a magnetic base.
(12)Position seal over pilot tool. Make sure you can read
Oil seal the words THIS SIDE OUT on seal. Pilot tool should
remain on crankshaft during installation of seal.
(13)Drive the seal into the block using Special Tool MB995080
and handle C-4171 until the tool bottoms out against
95059
the block.
seal Caution
If the seal is driven into the bl,&k past flush, this
._
may cause an oil leak. ‘,

M 8995060

CEN0133 I

CEN0134
 Piston, Connecting Rod
11 D-52 ENGINE OVERHAUL <2.0L (420A)> - and Cylinder a&k
INSPECTION 11302130015

CYLINPER BLOCK
(1) Clean cylinder block thoroughly and check all core hole
plugs for evidence of leaking.
(2) Examine block and cylinder bores for cracks or fractures.

CYLINDER BORE
(1) The cylinder walls should be checked for out-of-round
and taper with Tool C-119 or equivalent ,,The cylinder
bore out-of-round is 0.051 mm (.002, in.) maximum, and
Front B cylinder bore taper is 0.051 mm (.OQ2 in.) .maximum.
If the cylinder walls are badly scuffed or’scored, the cylin-
A der block should be rebored and honedStand new: pistons
and rings fitted. Whatever type ~of bortng %quipment is
used, boring and honing should be closely coordinated
with the fitting of pistons and rings so that specified clear-
ances may be maintained.
(2) Measure the cylinder bore at three levels in directions
A and B. Top measurement should be 10 mm (.39 in.)
down and bottom measurement should -be 10 mm (.39
in.) up from bottom of bore.
Standard value: 87.5 mm (3.445 in.) ~ “._

1
CENW74
’
I
PISTONS
(1) Piston and cylinder wall must be clean and dry. Piston
diameter should be measured 90 degrees to piston pin
at size location shown in the figure. Cylinder bores should
be measured halfway down the cylinder bore and trans-
verse to the engine crankshaft center Ilne. Correct piston
to bore clearance must be established in order to assure
quiet and economical operation.
Standard value: 0.012-0.044 mm (.0005-.OOi 7 in.)
CENOO75 (2) Pistons and cylinder bores should be measured at normal ’
room temperature, 21 “C. (70°F). ._

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 Piston, ConnqScting, Rocj
E N G I N E OVERhAUL <2.0L (420A)> - hd Cyiirider .Btbck-
PISTON RING
(1) Wipe cylinder bore clean. Insert ring and push down
with piston to ensure it is square in bore. The ring gap
measurement must be made with the ring positioning
at least 12 mm (.47 in.) from bottom of cylinder bore.
Check gap with feeler gauge.
Standard value:
Upper ring 0.23-0.52 mm (.OOQ-.020 In.)
Intermediate ring 0.49-0.78 mm (.OlQ-.031 in.)
Oil control ring 0.23-0.86 mm (.OOQ-.026 In.)
Limit:
Upper ring 0.8 mm (.031 in.)
Intermediate ring 1.0 mm (.03Q in.)
Oil control ring 1.0 mm (.03Q in.)

(2) Check piston ring to groove side clearance. .

Standard value: 0.0~5-?$~ ,;mm (.OOlO-.oq?s in.)
Limit: 0.10 mm (.004”in.) , I

‘,,a.’, I ,!
‘. . _
; _-

“..

CRANKSHAFT MAIN BEARINGS

The crankshaft is supported in five main bearings. All upper
bearing shells in the crankcase have oil grooves. All lower
bearing shells installed in the (bedplate) main bearing caps
are plain. Crankshaft end play is controlled by a flanged bear-
ing on the number three main bearing journal.

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 piston, Connwtipg RgQ
IIQ-54 ENGINE OVERHAUL <2.0L (42OA)> - ahd Cylinder Block ; r., ,. -I _

CONNECTING ROD BEARING CLEAR#CE _ .”

(1) Place a piece of Plastigage across the, entl’re width of
.the bearing shell in the beating cap approximately 6.35
mm off center and away -from the .oil hole. ‘In, ,addition,
suspect areas can be checked, by placing lPlastigage in
the suspect area.
(2) Before assembling the rod ‘caps with Plastlgage in place;
‘the crankshaft must be rotated until the connecting rod
being checked starts moving toward the top of the engine.,
Only then should the cap be .assembled~ and torqued
to the specification. - ._ I
Do not rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inaccurate re-
sults.
(3) Remove the bearing cap and compare the width of the
flattened Plastigage with the metric scale provided on
the package.
Standard value: 0.026-0.059 mm (.OOl-.0023 in.)
Limit: 0.075 mm (.003 in.)

CONNECTING ROD BEARING ‘CAP BqLT%‘-, , ~ I’ ’

(1) Since the connecting rod bearing cap bolts are torqued
using a new procedure, they should ,be’ examined BE-
StrtZched
Threads are not straight on line FORE reuse. If the threads are necked’ downiAreplace
.+
bolt Threads are straight qn line
, the bolts. ,:.>- ’ 3
(2) Necking can be checked by holding a scale or’straight
edge against the threads. If all the threads donot contact,
Un&etched bolt the scale, the bolt should be replaced. ,.I.,’ i ’
* ., .
CENOO51 ,’ ,

1 TSB Revision I
ENGINE OVERHAUL <2.0L (42OA)> ‘-“Cr~~kah&f :/

CRANKSHAFT
REMOVAL
Procedures after removing crankshaft sprocket, oil pan, pis-
tons and connecting rods.
(1) Using Tool MB995022, remove front crankshaft oil seal.
Be careful not to damage the seal surface of cover.
(2) Pry out rear seal with screwdriver. Be careful not to nick
or damage crankshaft flange seal surface or retainer bore.

(3) Remove main bearing cap bedplate.

(4) Remove bearing lower.
(5) Remove crankshaft.
(6) Remove bearing upper.
(7) Remove knock sensor.
(8) Remove oil pressure switch.
(9) Remove oil level gauge (dipstick).

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 ENGINE OVERHAUL <2.0L (42OA)> - Crankshaft

INSTALLATION kiilooo?q
(1) Install oil level gauge (dipstick).
(2) Install oil pressure switch. ,:I :. ! ‘.‘I
,’ ‘,
#,”
:r ,.‘,T ,:T’ kd*iI ;
.:
.Y it 1” 1 ;y ,. F.^.
I, :- ,“, ,/, , ’
., /4, ‘, , *
‘. -. “;;.;, ).’ ,:; if:
/ I Jr’ L-
‘3

(3) Install knock sensor. Tighten knock sensor to 10 Nm

(7 ftlbs.) torque. Over or under tightening effects knock
sensor performance, possibly causing improper spark con-
t r o l .

(4) Select proper thickness main bearing shells by referring

to CRANKSHAFT BEARING CLEARANCE.

CENO080

NOTE
Upper and lower No. 3 bearing halves are flanged to
carry the crankshaft thrust loads and are NOT interchange-
able with any other bearing halves in the engine. Bearing
shells are available in standard and the following under-
sized:
0.016 mm, 0.032 mm, 0.250 mm.
Never install an undersize bearing that will reduce clear-
ance below specifications.
CENO078

(5) Install the main bearing shells with the lubrication groove
in the cylinder block.

Oil holes CENO081

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ENGINE OVERHAUL <2.0L (420A)> - .Crankshdfi
NOTE
All upper bearing shells in the crankcase have oil grooves.
All lower bearing shells installed in the (bedplate) main
bearing caps are plain. Crankshaft end play is controlled
by a flanged bearing on the number three main bearing
journal.

(6) Make certain oil holes in block line up with oil hole in
bearings and bearing tabs seat in the bkxk tab slots.
(7) Oil the bearings and, journals and install,i crankshaft. ;
Caution 2
Do no? get oil on bedplate m&ting rr&face:
If may effect the sealer ability toi geai
,::,. the @edplate,
to cylinder block. I,,
” 0.

(8) Apply 1.5 to 2.0 mm (.059 to .078 in.) bead of Loctite

19614 to cylinder block as shown in’ the figure.
(9) Install main bearing cap bedplate together with lower’
bearing shells.
Caution
Use only the specified anaefroblc sealer “on r* &e’
bedplate or damage ma9 occur to the’;&ng[n&. ’
,’
/ / s i, ’

CEN0129

; .,. .

‘9,
’
i .
‘, ;

; .:

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11 D-58 ENGINE OVERHAUL <2.0L (420A)> - Crankih@ft I . L

(1O)Before installing the bolts, the threads should be oiled

with engine oil.

(1l)lnstall main bearing bedplate to engine block bolts (1

thru 10) finger tight, then torque main bearing bolts to
75 Nm (55 ftlbs.) in sequence shown in the figure.
(12)!nstall main bearing bedplate to engine block bolts (A
thru K) finger tight, then torque each bolt to 28 Nm (20
ft.lbs.) in sequence shown in the figure.

(13)lnstall crankcase baffle into the opening in the b&k:’

Crankcase Attach baffle to main bearing cap fasteners.
baffle
/,
,I

QN0127

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 ENGINE OVERHAUL <2.0L (420A)> - Cratik~haft
(14)Place new front seal into opening with seal spring towards
the inside of engine. Install seal by using Tool MB995022
until flush with oil pump cover.

Caution
if burr or scratch is present on the crankshaft edge
(chamfer), cleanup with 400 grit sand paper to prevent
seal damage during instailatlon of new seal.
NOTE
When installing seal, no lube on seal is needed.
(15)Place Special Tool MB995059 on crankshaft. This is a
pilot tool with a magnetic base.
(16)Position seal over pilot tool. Make sure you can read
Oil seal CEN0132 the words THIS SIDE OUT on seal. Pilot tool should
remain on crankshaft during installation of seal.
(17)Drive the seal into the block using Special Tool MB995060
95059 and handle C-4171 until the tool bottoms out against
the block.
seal Caution
If the seal is driven into the block past flush, this
may cause an oil leak.

I I CEN0133

CEN0134

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11 D-60 E N G I N E OVERHAUL <2.0L (42oA)> - Cran\<h$t ,~, _I, . . I ,.
INSPECTION 113o2laoo10

CRANKSHAFT MAIN JOURNALS

(1) The crankshaft journals should be checked for excessive
wear, taper and scoring. Limits of taper or out-of-rcund
on any crankshaft journals should be held. to 0.025 mm.
(.OOl in.). Journal grinding should not exceed 0.305 mm
(.012 in.) under the standard joumal‘diameter. Do NOT
grind thrust faces of kumber 3 -main journal. Do NOT
nick crank pin or journal fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out all
passages. ,
;P 0
Caution .
With the nodular cast iron crankshafts ased It Is lmpor-
tant that the final paper or cloth polist%fter any journal
regrind be in the same direction as normal rotation’
in the engine.

(, :: : .,
‘,,.3
I’
.,’
;

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 ENGINE OVERH#JL <2.0L (42OA)a - Craf@tS~R
CRANi@HA~ BEARING CLEARANCE
.f. (1) The. total: clearance of the main bearings can only be
., ;, determined by removing the weight of the crankshaft.
j I This is accomplished by having the engine turned upside
down on the engine stand. This will remove all the crank-
.shaft weight off the bearing surface.
(2) Place, a piece of Plastigage across the entire width of
the bearing shell in the bedplate approximately 6.35 mm
(.25 in.) off center and away from the oil holes. In addition,
suspect areas can be checked by placing the Plastigage
in the suspect area.
Torque the bedplate bolts of the bearing being checked
to the proper specifications.
Caution
Do not rotate crankshaft, or the Plastigage may be
smeared.
(3) Remove the bedplate and compare the width of the flat-
tened Plastigage with the metric scale provided on the
package.
Standard value: 0.022-0.062 mm (.0009-.0024 in.)

MAIN BEARING BOLTS

(1) Since the main bearing bolts are torqued using a new
procedure, they should be examined BEFORE reuse.
Stretched If the threads are necked down, replace the bolts.
Threads are straight on line
bolt , (2) Necking can be checked by holding a scale or straight
edge against the threads. If all the threads do not contact
the scale, the bolt should be replaced.
Unstretched bolt

CEN0051

CHECKING CRANKSHAFT END PLAY

(1) Mount a dial indicator to front of engine, locating probe
on nose of crankshaft.
(2) Move crankshaft all the way to the rear of its travel using
a lever inserted between a main bearing cap and a crank-
shaft cheek, using care not to damage any bearing sur-
face, Do not loosen main bearing cap.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and read the
dial indicator.
CENOO79
Standard value: 0.09-0.24 mm (.0035-.0094 in.)
Limit: 0.37 mm (.015 in.)
(5) Replace No. 3 main bearing if limit is exceeded and re-
measure.
(6) Replace crankshaft if limit is still exceeded.
11 D-62 ENGINE OVERHAUL <2.0L (42OA)> - Crhksbatit ,.
OPTIONAL CRANKSHAFT END PLAY CHECK
(1) Move crankshaft all the way to the rear of its travel using
a lever inserted between a main bearing cap and a crank-
shaft cheek, using care not to damage any bearing sur-
face. Do not loosen main bearing cap.
(2) Use a feeler gauge between number three thrust bearing
and machined crankshaft surface to determine end play.

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