Cam bearing cap chamfer
Some Chrysler engines may exhibit a high pitched snapping noise (not a low metallic knock) at the upper right (passenger) side between idle and 1,400 rpm at normal operating temperature. The noise is irregular and will increase with engine rpm.
The repair involves chamfering the bore radius on camshaft bearing caps L2 through L5 and R2 through R5.
Affected engines include 2.0, 2.4 DOHC and 2.4 turbo. Vehicles include 2001-2004 Sebring and Stratus, 2002-2004 Jeep Liberty and Cherokee, 2003-2004 Neon, 2001-2004 PT Cruiser, 2001-2003 Voyager and Town & Country and 2003-2004 Jeep Wrangler.
- Remove the cylinder head cover.
- Remove the L2 cam bearing cap. NOTE: Do not remove the L1/R1 or L6 cam bearing caps and do not loosen these cap fasteners. Only remove one cam bearing cap at a time.
- Lightly chamfer the two bore radius edges with a small hand file, creating a 45-degree chamfer, 1.0 to 1.5mm in width along the edge of each bore radius. Be careful not to scratch the cam bearing cap bore surfaces.
- Clean to remove any aluminum filings.
- Reinstall the L2 cam bearing cap by loosely installing the fasteners. Prior to and during the torquing of each fastener, twist the cam bearing cap by hand in a clockwise direction, as viewed from the top of the engine. Torque M6 fasteners to 105 in.-lbs. (12 Nm) while maintaining a clockwise twisting force on the cam bearing cap.
- Repeat steps 2 through 4 for cam bearing caps L3, L4, L5, R2, R3, R4, R5 and R6.