By Eric Seifert, ALLDATA Automotive Technical Editor

A strange noise may cause concern to owners of some Chrysler vehicles.
The noise may occur when the vehicle is in park, and the engine is
running between idle and 1,400 rpm at normal operating temperature. The
sound is heard at the upper end of the engine (cylinder head) toward
the right front side (passenger side), and is irregular, not periodic
or harmonious. The frequency of the noise will increase with rpm. The
sound is more of a high-pitched “snapping” noise, not a low metallic
knock.

If the customer describes the noise and the installer determines that
the sound is coming from the described location, perform the repair
procedure. The procedure involves chamfering the bore radius on cam
bearing caps L2 through L5 and R2 through R5.

Note: This procedure applies to 2001-2004 vehicles equipped with a 2.0L,
2.4L DOHC or 2.4L Turbo engine.

Repair Procedure

Review safety procedures in ALLDATA Repair before beginning.

1. Remove the cylinder head cover.

2. Remove L2 cam bearing cap (see Figure 1).

Note: Do not remove the L1/R1 or L6 cam bearing caps, or loosen the fasteners. Only remove one cam bearing cap at a time.

3. Lightly chamfer the two bore radius edges with a small hand
file, creating a 45° chamfer 1.0 to 1.5 mm in width along the edge of
each bore radius (see Figure 2).

Caution: Be careful not to scratch the bore surface of the cam bearing cap(s). Chamfer both bore radius.

4. Clean the part to remove any aluminum filings prior to reinstalling.

5. Reinstall the L2 cam bearing cap by loosely assembling 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.

6. Repeat steps 2 through 4 for cam bearing caps L3, L4, L5, R2, R3, R4, R5 and R6.

7. Reinstall the cylinder head cover.

8. Verify the repair.

– Courtesy of ALLDATA