Dodge Caliber. Manual — part 1073
1.
Cylinder head must be flat within 0.1 mm (0.004
in.).
2.
Inspect camshaft bearing journals for scoring.
3. Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
4. Using a small hole gauge and a micrometer, mea-
sure valve guides in 3 places top (1), middle (2),
and bottom (3). (Refer to 9 - ENGINE - SPECIFI-
CATIONS) Replace guides if they are not within
specification.
5. Check valve guide height.
6. Prior to installing cylinder head, the cylinder block
should be checked for flatness (Refer to 9 -
ENGINE/ENGINE BLOCK - INSPECTION).
INSTALLATION - CYLINDER HEAD
NOTE: Ensure cylinder head bolt holes in the
block are clean, dry (free of residual oil or cool-
ant), and threads are not damaged.
NOTE: The Cylinder head bolts should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts should be replaced.
Necking can be checked by holding a scale or straight
edge against the threads. If all the threads do not con-
tact the scale (2), the bolt should be replaced.
PM
ENGINE 2.0L WORLD
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CAUTION: Always replace the variable valve timing
filter screen (3) when servicing the head gasket or
engine damage could result.
1. Replace the variable valve timing filter screen (3).
2. Place two pea size dots of RTV (1) on cylinder
block as shown.
3. Position the new cylinder head gasket on engine
block with the part number facing up. Ensure gas-
ket is seated over the locating dowels in block.
4. Place two pea size dots of RTV (1) on cylinder
head gasket as shown.
NOTE: The head must be installed within 15 min-
utes before the RTV skins.
5. Position cylinder head onto engine block.
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ENGINE 2.0L WORLD
PM
NOTE: The front two cylinder head bolts do not
have captured washers. The washers must be
installed with the bevel up towards the bolt head.
6. Install washers (1) for the front two cylinder head
bolts.
7. Before installing the bolts, the threads should be
lightly coated with engine oil.
8. Install the cylinder head bolts and torque in the
sequence shown above.
•
First: All to 30 N·m (25 ft. lbs.)
•
Second: All to 61 N·m (50 ft. lbs.)
•
Third: All to 61 N·m (45 ft. lbs.)
•
Fourth: All an additional 90°
CAUTION: Do not use a torque wrench for the
Fourth step.
9. Install camshafts. (Refer to 9 - ENGINE/CYLINDER
HEAD/CAMSHAFT(S) - INSTALLATION).
10. Install cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER - INSTALLA-
TION).
11. Install maniverter/exhaust manifold to cylinder head. Torque fasteners to 34 N·m (25 ft.lbs.).
12. Install heat shields.Torque fasteners to 9 N·m ( ).
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ENGINE 2.0L WORLD
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13. Install oxygen sensor in maniverter.
14. Install ground strap at right rear of cylinder head.
15. Install coolant manifold.
16. Install intake manifold.
17. Install intake manifold bolts and torque to 24 N·m (18 ft.lbs.).
18. Install upper radiator hose retaining bracket.
19. Install timing chain (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTAL-
LATION).
20. Install timing chain cover, torque m6 bolts to 12 N·m (105 in.lbs.) and m8 bolts to 23 N·m (17 ft.lbs.).
21. Connect cam sensor wiring connector.
22. Install spark plugs and torque to 27 N·m (20 ft.lbs.).
23. Install ignition coils and torque to 8 N·m (70 in.lbs.).
24. Install power steering pump reservoir/bracket to cylinder head.
25. Install exhaust pipe to manifold. Torque fasteners to 28 N·m (20 ft. lbs.).
26. Install accessory drive belts (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
27. Connect engine coolant temperature sensor connector.
28. Connect upper radiator hose. Connect heater hoses to thermostat housing.
29. Install heater tube support bracket to cylinder head.
30. Install fastener attaching dipstick tube to lower intake manifold
31. Connect fuel supply line quick-connect at the fuel rail assembly (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCEDURE).
32. Fill cooling system (Refer to 7 - COOLING/ENGINE - STANDARD PROCEDURE).
33. Connect negative cable to battery.
34. Install clean air hose and air cleaner housing (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - INSTALLATION).
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PM
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