Dodge Caliber. Manual — part 1096
30. Install inspection cover (1).
31. Install transaxle electrical connectors.
32. Connect trans cooler lines.
33. Install coolant hoses at transmission cooler.
34. Install axles.
35. Install ball joint pinch bolts and tighten.
36. Install axle nuts and tighten.
37. Install splash shields.
38. Install wheels.
39. Install new oil filter.
40. Lower vehicle.
41. Install transaxle filler tube.
42. Install upper idler pulley.
43. Install power steering pump.
44. Install power steering line support bracket.
45. Install power steering pump.
46. Install accessory drive belt.
47. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, Oil pressure sensor, gen-
erator, Coolant temperature sensor at block, and block heater.
48. Install intake manifold and tighten bolts.
49. Install throttle body support bracket (1).
50. Install engine oil dip stick.
51. Install PCV hose to valve cover.
52. Connect manifold flow control valve and electronic
throttle control electrical connectors and fasten
harness to intake.
53. Install vacuum lines at throttle body and intake
manifold.
54. Install intake air tube on throttle body.
55. Connect engine harness electrical connectors.
56. Install upper radiator support bracket.
57. Install coolant hoses at coolant manifold.
58. Install grill trim panel.
59. Install coolant reservoir and connect hose.
60. Connect fuel line to fuel rail.
61. Install battery tray and battery.
62. Connect battery cables.
63. Install air cleaner housing and connect inlet air hose.
64. Install fresh air inlet.
65. Fill with coolant.
66. Fill with oil.
CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the
A/C system. Failure to follow this caution will result in serious A/C compressor damage.
67. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
68. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
69. Start engine and check for leaks.
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ENGINE 2.4L WORLD
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SPECIFICATIONS
2.4L ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Type
In-Line OHV, DOHC
Number of Cylinders
4
Firing Order
1-3-4-2
Compression Ratio
9.5:1
Max. Variation Between Cylinders
25%
Displacement
2.4 Liters
148 cu. in.
Bore
88 mm
3.465 in.
Stroke
97 mm
3.819 in.
Compression Pressure
1172-1551 kPa
170-225 psi
CYLINDER BLOCK
DESCRIPTION
SPECIFICATION
Metric
Standard
Material
Cast Aluminum
Cylinder Bore Diameter
87.4924-87.5076 mm
3.4446-3.4452 in.
A
88.0-88.010
3.4645-3.4649 in.
B
88.010-88.020
3.4649-3.4653 in.
C
88.020-88.030
3.4653-3.4657 in.
Out-of-Round (Max.)
0.051 mm
0.002 in.
Taper (Max.)
0.051 mm
0.002 in.
PISTONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Piston Diameter
87.456-87.474 mm
3.4431-3.4439 in.
Clearance @ 24.6 mm (0.551 in.)
from bottom of skirt (Non-Turbo)
0.018-0.0516 mm
0.0007-0.0020 in.
Clearance @ 22 mm (0.866 in.)
from bottom of skirt (Turbo)
0.046-0.064 mm
0.0018-0.0025 in.
Weight
345-355 grams
12.17-12.52 oz.
Land Clearance (Diametrical)
0.563-0.621 mm
0.022-0.024 in.
Piston Length
66.25 mm
2.608 in.
Piston Ring Groove Depth No. 1
3.946-4.045 mm
0.155-0.159 in.
Piston Ring Groove Depth No. 2
4.555-4.680 mm
0.179-0.184 in.
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ENGINE 2.4L WORLD
PM
DESCRIPTION
SPECIFICATION
Metric
Standard
Piston Ring Groove Depth No. 3
4.108-4.220 mm
0.162-0.166 in.
PISTON RINGS
DESCRIPTION
SPECIFICATION
Metric
Standard
Ring Gap-Top Compression Ring
0.25-0.51 mm
0.0098-0.020 in.
Wear Limit
0.8 mm
0.031 in.
Ring Gap-2nd Compression Ring
0.23-0.48 mm
0.009-0.018 in.
Wear Limit
0.8 mm
0.031 in.
Ring Gap-Oil Control Steel Rails
0.25-0.64 mm
0.009-0.025 in.
Wear Limit
1.0 mm
0.039 in.
Ring Side Clearance-Compression
Rings
0.030-0.080 mm
0.0011-0.0031 in.
Wear Limit
0.10 mm
0.004 in.
Ring Side Clearance-Oil Ring Pack
0.012-0.178 mm
0.0004-0.0070 in.
Ring Width-Compression Rings
1.47-1.50 mm
0.057-0.059 in.
Ring Width-Oil Ring Pack
2.72–2.88 mm
0.107–0.1133 in.
CONNECTING ROD
DESCRIPTION
SPECIFICATION
Metric
Standard
Bearing Clearance
0.025–0.071 mm
0.0009–0.0027 in.
Wear Limit
0.075 mm
0.003 in.
Bore Diameter-Piston Pin
20.96–20.98 mm
0.8252–0.8260 in.
Bore Diameter-Crankshaft End
52.993-53.007 mm
2.0863-2.0868 in.
Side Clearance
0.13–0.38 mm
0.005–0.015 in.
Wear Limit
0.40 mm
0.016 in.
Weight-Total (Less Bearing)
565.8 grams
19.96 oz.
CRANKSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Connecting Rod Journal Diameter
49.984 - 50.000 mm
1.968 - 1.9685 in.
Main Bearing Journal Diameter
59.992 - 60.008 mm
2.362 - 2.3625 in.
Journal Out-of-Round (Max.)
0.0035 mm
0.0003 in.
Journal Taper (Max.)
0.007 mm
0.0001 in.
PM
ENGINE 2.4L WORLD
9 - 1673
DESCRIPTION
SPECIFICATION
Metric
Standard
End Play
0.09 - 0.24 mm
0.0035 - 0.0094 in.
Wear Limit
0.38 mm
0.015 in.
Main Bearing Diametrical Clearance
0.018 - 0.062 mm
0.0007 - 0.0024 in.
CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER
DSECRIPTION
SPECIFICATION
Metric
Standard
Front Journal
Intake
30.000 - 30.021 mm
1.1810 - 1.1819 in.
Exhaust
40.000 - 40.021 mm
1.5747 - 1.5756 in.
Journals No. 1-4
24.000 - 24.021 mm
0.9448 - 0.9457 in.
CAMSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Journal Diameter No. 1
29.964 - 29.980 mm
1.179 - 1.180 in.
Journal Diameter No. 2-5
23.954 - 23.970 mm
0.943 - 0.944 in.
Bearing Clearance - Diametrical
0.030 - 0.067 mm
0.0011 - 0.0026 in.
End Play
0.11 - 0.25 mm
0.004 - 0.009 in.
Max Lift @ 0.2mm (0.007 in.) lash
Intake
9.2 mm
(0.362 in.)
Max Lift @ 0.28mm (0.011 in.) lash
Exhaust
8.42 mm
(0.331 mm)
Intake Valve Timing*
Closes (ABDC)
49.3°
Opens (ATDC)
10.3°
Duration
219°
Exhaust Valve Timing*
Closes (BTDC)
8.45°
Opens (BBDC)
45°
Duration
216.55°
Valve Overlap @ 0.5mm (0.019 in.)
w/ VVT in lock-pin position
18.75°
*
All reading in crankshaft degrees at 0.5 mm (0.019 in.) valve lift.
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ENGINE 2.4L WORLD
PM
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