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Engine "tapping" Noise.

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  #1 (permalink)  
Old 03 Jan 2005, 01:18 am
Young Cruiser
Join Date: Dec 2003
Location: Napoleon Twp., MI.
Posts: 67
Default Engine "tapping" Noise.

I've recenly noticed an intermittant tapping noise from my PT's engine. The dealer brought up a TSB for an irregular engine snapping sound (#09-007-04). The repair consists of chamfering the bore radius of the cam bearing caps (L2 thru 5 and R2 thru 5). Has anyone out there had this done and if so, did it cure the engine noise?
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Old 03 Jan 2005, 02:32 am
Dedicated Cruiser
Join Date: Jan 2003
Location: Washington State, USA.
Posts: 2,525

TSB #: 09-007-04
GROUP: Engine
DATE: March 2, 2004
This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.
Irregular Engine Snapping Sound
This bulletin involves chamfering the bore radius on cam bearing caps
L2 through L5 and R2 through R5.
2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan
2002 - 2004 (KJ) Liberty
2002 - 2004 (KJ) Cherokee (International Markets)
2003 - 2004 (PL) Neon
2001 - 2004 (PT) PT Cruiser
2001 - 2004 (RG) Chrysler Voyager (International Markets)
2001 - 2004 (RS) Town & Country/ Caravan/Voyager
2003 - 2004 (TJ) Wrangler
NOTE: This bulletin applies to vehicles equipped with a 2.0L, 2.4L DOHC or 2.4L
Turbo engine (sales code ECC, EDZ, ED1, EDV, ED2 or EDT).
The sound may be noticed when the engine is idling in park between idle rpm and 1400
rpm at normal operating temperature. The sound is on the upper end of the engine
(cylinder head) towards the front of the engine or passenger side (right side). The sound is
irregular, not periodic or harmonious. The frequency of the sound will increase with RPM.
The sound is more of a higher pitch snapping noise not a low metallic knock.
If the vehicle operator describes the Symptom/Condition and the technician determines
that the sound is from the upper end of the engine (cylinder head) towards the front of
the engine or passenger side (right side), perform the Repair Procedure.
09-007-04 -2-
1. Remove the cylinder head cover (Refer to information available in TechCONNECT
2. Remove L2 cam bearing cap (Fig. 1).
NOTE: Do not remove the #L1/R1 or L6 cam bearing caps, or loosen the fasteners.
NOTE: 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 (Fig. 2).
CAUTION: Be careful not to scratch bore surface of cam bearing
cap. Chamfer both bore radius.
4. Clean part to remove any aluminum filings prior to reinstalling.
-3- 09-007-04
5. Reinstall L2 cam bearing cap by loosely assembling 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 12 N·m (105 in. lbs.)
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.
Reimbursable within the provisions of the warranty.
Labor Operation
52 Improperly Machined

Good luck. [8]
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Old 03 Jan 2005, 12:50 pm
Fanatic Cruiser
Join Date: Jan 2004
Location: louisville, kentucky, USA.
Posts: 658

I had it done on my 2004 pt turbo lite. It is no big deal to repair. It is a very simple repair for the dealer and dont worry that they will damage your engine. Have it done and you engine will not tap at all. If you decide that you do not want it done the tapping will not do any damage at all or affect the engine performance at all. As a matter of fact over a long period of time it way go away or become less noticable....My opinion is to have it done...Takes about 11/2 hours to repair....
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Old 03 Jan 2005, 01:32 pm
Young Cruiser
Join Date: Dec 2003
Location: Napoleon Twp., MI.
Posts: 67

Thanks for the responses. It sure helps to know that the procedure works. I've done enough engine work over the years to get nervous about anyone else opening up my engine. I guess I'm getting old or lazy or both, because ten years ago I'd have done this job myself!
\'07 Cognac Town and Country Touring - no turbo
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  #5 (permalink)  
Old 22 Nov 2016, 11:46 am
Fresh Cruiser
Join Date: May 2011
Posts: 22
Default Re: Engine "tapping" Noise.

Did this fix your issue? Does anyone have a picture of the process?

I have been collecting my notes on this thread:
Engine sounds like Diesel on cold start - engine clacking until warm

Last edited by mr_mahoney; 22 Nov 2016 at 12:12 pm.
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