Dodge Caliber. Manual — part 1109
BEARINGS-MAIN
STANDARD PROCEDURE - MAIN BEARING SELECTION
NOTE: There are three different possibilities for the upper main bearings and five different lower main bear-
ings. The upper and lower bearing shells are not interchangeable.
The lower main bearing identification is stamped in the nose of the crankshaft (1). There are 5 different bearing
sizes available 0 through 4.
CRANKSHAFT IDENTIFICATION
LOWER CRANKSHAFT BEARING SELECTION
JOURNAL DIAMETER
GRADE
DIMENSION
LOWER MAIN BEARING
SIZE CLASSIFICATION
LOWER MAIN BEARING
DIMENSION
0
52 mm
0 (Pink or Red)
2 mm
1
52 mm
1 (Black)
2 mm
2
52 mm
2 (No Color)
2 mm
3
52 mm
3 (Green)
2 mm
4
52 mm
4 (Blue)
2 mm
The upper main bearing shell identification is located in the middle of cylinder block on the right side of the engine
when viewing from the flywheel. There are three different size bearings available.
UPPER MAIN BEARING SELECTION
CYLINDER BLOCK IDENTIFICATION
UPPER CRANKSHAFT BEARING SELECTION
MAIN BEARING GRADE
DIMENSION
UPPER MAIN BEARING
SIZE CLASSIFICATION
UPPER MAIN BEARING
DIMENSION
1
56 mm
1 (Black)
2 mm
2
56 mm
2 (No Color)
2 mm
3
56 mm
3 (Green)
2 mm
PM
ENGINE 2.4L WORLD
9 - 1723
BEARINGS-CONNECTING ROD
STANDARD PROCEDURE
CONNECTING ROD - FITTING
There are three different sizes of rod bearings available. Connecting rod bearing identification can be found on the
nose of the crankshaft. Use the table below for proper bearing selection.
CONNECTING ROD BEARING SELECTION
CRANKSHAFT PIN
DIAMETER GRADE
DIMENSION
CONNECTING ROD
BEARING
CLASSIFICATION
CONNECTING ROD
BEARING DIMENSION
1
48 mm
1 (Black)
1.5 mm
2
48 mm
2 (No Color)
1.5 mm
3
48 mm
3 (Green)
1.5 mm
1. For measuring connecting rod bearing clearance
procedure and use of Plastigage (Refer to 9 -
ENGINE - STANDARD PROCEDURE) For bearing
clearance refer to Engine Specifications. (Refer to
9 - ENGINE - SPECIFICATIONS).
NOTE: The rod bolts should not be reused.
2. Before installing the NEW rod bolts the threads and
under the bolt head should be oiled with clean
engine oil.
3. Install each bolt finger tight then alternately torque
each bolt to assemble the cap properly.
4. Tighten the connecting rod bolts using the 2 step
torque-turn method. Tighten according to the fol-
lowing values:
CAUTION: Do not use a torque wrench for the sec-
ond step.
1. Tighten the bolts to 27 N·m (20 ft. lbs.).
2. Tighten the connecting rod bolts an additional 90°.
5. Using a feeler gauge, check connecting rod side
clearance. Refer to clearance specifications (Refer
to 9 - ENGINE - SPECIFICATIONS).
9 - 1724
ENGINE 2.4L WORLD
PM
RINGS-PISTON
STANDARD PROCEDURE
PISTON RING - FITTING
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 (0.50 inch) from bottom
of cylinder bore. Check gap with feeler gauge.
Refer to Engine Specifications.
2. Check piston ring to groove side clearance. Refer
to Engine Specifications.
PM
ENGINE 2.4L WORLD
9 - 1725
REMOVAL
1. Using a suitable ring expander, remove upper and
intermediate piston rings.
2. Remove the upper oil ring side rail, lower oil ring
side rail and then oil ring expander from piston.
3. Clean ring grooves of any carbon deposits.
INSTALLATION
NOTE: The identification mark on face of upper
and intermediate piston rings must point toward
top of piston.
CAUTION: Install piston rings in the following
order:
1. Oil ring expander.
2. Upper oil ring side rail.
3. Lower oil ring side rail.
4. No. 2 Intermediate piston ring.
5. No. 1 Upper piston ring.
1. Install oil ring expander.
2. Install upper side rail first and then the lower side
rail. Install the side rails by placing one end between the piston ring groove and the oil ring 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.
NOTE: The compression rings are marked Y1 for the upper compression ring and Y2 for the second com-
pression ring. These markings must face upward.
3. Install No. 2 piston ring and then No. 1 piston ring.
4. Position piston ring end gaps as shown in.
5. Position oil ring expander gap at least 45° from the
side rail gaps but not on the piston pin center or
on the thrust direction. Staggering ring gap is
important for oil control.
9 - 1726
ENGINE 2.4L WORLD
PM
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