Dodge Caliber. Manual — part 1064
ENGINE 2.0L WORLD
TABLE OF CONTENTS
page
page
ENGINE 2.0L WORLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1545
DIAGNOSIS AND TESTING
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . 1550
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1550
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . 1551
THREADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1552
PLASTIGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1555
2.4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1568
ELEMENT-AIR CLEANER
HOUSING-AIR CLEANER
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1576
DIAGNOSIS AND TESTING
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 1576
CAMSHAFT(S)
MEASURING CAMSHAFT END PLAY . . . . . . . 1583
COVER-CYLINDER HEAD
TAPPETS-VALVE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1592
STANDARD PROCEDURE - MEASURING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1592
VALVES & SEATS-INTAKE/EXHAUST
SPRINGS & SEALS-VALVE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1597
INSTALLATION
PHASERS-CAMSHAFT
ENGINE BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1601
STANDARD PROCEDURE
CYLINDER BORE HONING . . . . . . . . . . . . . . . . 1601
CRANKSHAFT
MEASURING CRANKSHAFT END PLAY . . . . 1603
SEAL-CRANKSHAFT OIL FRONT
SEAL-CRANKSHAFT OIL REAR
PISTON & ROD-CONNECTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1610
STANDARD PROCEDURE
PISTON TO CYLINDER BORE FITTING . . . . . 1610
PM
ENGINE 2.0L WORLD
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BEARINGS-MAIN
STANDARD PROCEDURE - MAIN BEARING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1613
BEARINGS-CONNECTING ROD
CONNECTING ROD - FITTING . . . . . . . . . . . . . 1614
RINGS-PISTON
PISTON RING - FITTING . . . . . . . . . . . . . . . . . . 1615
DAMPER-VIBRATION
FRAME-LADDER
ENGINE MOUNTING
MOUNT-LEFT
MOUNT-RIGHT
MOUNT-FRONT
MOUNT-REAR
LUBRICATION
CHECKING ENGINE OIL PRESSURE . . . . . . . 1625
OIL
FILTER-OIL
PAN-OIL
VALVE-OIL PRESSURE RELIEF
PUMP-OIL
SENSOR/SWITCH-ENGINE OIL PSI
COOLER-OIL
MANIFOLD-INTAKE
INTAKE MANIFOLD LEAKS . . . . . . . . . . . . . . . . 1639
LOWER INTAKE MANIFOLD . . . . . . . . . . . . . . . 1639
LOWER INTAKE MANIFOLD . . . . . . . . . . . . . . . 1640
MANIFOLD-EXHAUST
COVER-TIMING CHAIN
CHAIN AND SPROCKETS-TIMING
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1647
INSTALLATION
TENSIONER-TIMING CHAIN
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ENGINE 2.0L WORLD
PM
ENGINE 2.0L WORLD
DESCRIPTION
The 2.0 Liter (122 cu. in.) in-line four cylinder engine is a double over head camshaft with mechanical lash buckets
and four valves per cylinder design. This engine is NOT free-wheeling; meaning that the pistons will contact the
valves in the event of a timing chain failure.
The cylinders are numbered from front of the engine to the rear. The firing order is 1–3–4–2.
The engine identification number is located on the rear of the cylinder block.
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine main-
tenance.
These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine
idles rough and stalls).
Refer to the Engine Mechanical and the Engine Performance diagnostic charts, for possible causes and corrections
of malfunctions (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING - MECHANICAL) (Refer to 9 - ENGINE - DIAG-
NOSIS AND TESTING - PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING).
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that cannot be iso-
lated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the
following:
•
Cylinder Compression Pressure Test
•
Cylinder Combustion Pressure Leakage Test
•
Engine Cylinder Head Gasket Failure Diagnosis
•
Intake Manifold Leakage Diagnosis
•
Mechanical Valve Tappet Noise Diagnosis
•
Engine Oil Leak Inspection
PM
ENGINE 2.0L WORLD
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ENGINE DIAGNOSIS - PERFORMANCE
CONDITION
POSSIBLE CAUSE
CORRECTION
ENGINE WILL NOT START
1. Weak battery.
1. Test battery. Charge or replace as
necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter.
3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit.
4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap.
5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system.
6. Clean system and replace fuel
filter.
7. Faulty fuel pump.
7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing.
8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH
1. Idle speed too low.
1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture.
2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage.
3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s).
4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
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ENGINE 2.0L WORLD
PM
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