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2.4L Engine - Service Information: Specifications Dodge Avenger II facelift

Mechanical 37 illustrations ~921 words

2.4L ENGINE SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
TypeIn-Line OHV, DOHC
Number of Cylinders4
Firing Order1-3-4-2
Compression Ratio10.5:1
Displacement2.4 Liters146.5 cu. in.
Bore88 mm3.465 in.
Stroke97 mm3.819 in.
Compression Pressure1172 - 1551 kPa170 - 225 psi
Max. Variation Between Cylinders25%

GENERAL SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
MaterialCast Aluminum
Cylinder Bore Diameter
A88.000 - 88.010 mm3.4645 - 3.4649 in.
B88.010 - 88.020 mm3.4649 - 3.4653 in.
C88.020 - 88.030 mm3.4653 - 3.4657 in.
Cylinder Bore Out-of-Round (Max.)0.020 mm0.0008 in.
Cylinder Bore Diameter Taper (Max.)0.028 mm0.001 in.
Main Bearing Bore Diameter
156.000 - 56.006 mm2.2047 - 2.2049 in.
256.006 - 56.012 mm2.2049 - 2.2051 in.
356.012 - 56.018 mm2.2051 - 2.2054 in.
Main Bearing Bore Diameter Taper (Max.)0.0082 mm0.0003 in.

CYLINDER BLOCK

DESCRIPTIONSPECIFICATION
MetricStandard
Piston Diameter
A87.995 - 88.015 mm3.4644 - 3.4652 in.
B88.005 - 88.025 mm3.4648 - 3.4656 in.
C88.015 - 88.035 mm3.4652 - 3.4659 in.
Clearance to Bore(-0.015) - 0.015 mm(-0.0006) - 0.0006 in.
Weight302 - 312 grams10.65 - 11.00 oz.
Land Clearance (Diametrical)0.60 - 0.73 mm0.0236 - 0.0287 in.
Piston Length51.5 mm2.028 in.
Piston Ring Groove Depth No. 13.51 - 3.68 mm0.1382 - 0.0256 in.
Piston Ring Groove Depth No. 24.05 - 4.25 mm0.1594 - 0.1673 in.
Piston Ring Groove Depth No. 32.70 - 2.90 mm0.1063 - 0.1142 in.

PISTONS

DESCRIPTIONSPECIFICATION
MetricStandard
Ring Gap-Top Compression Ring0.15 - 0.30 mm0.0059 - 0.0118 in.
Wear Limit0.8 mm0.031 in.
Ring Gap-2nd Compression Ring0.30 - 0.45 mm0.0118 - 0.0177 in.
Wear Limit0.8 mm0.031 in.
Ring Gap-Oil Control Steel Rails0.20 - 0.70 mm0.0079 - 0.0276 in.
Wear Limit1.0 mm0.039 in.
Ring Side Clearance-Compression Rings0.03 - 0.07 mm0.1182 - 0.0028 in.
Wear Limit0.10 mm0.004 in.
Ring Side Clearance-Oil Ring Pack0.06 - 0.15 mm0.0024 - 0.0059 in.
Ring Width-Top Compression Ring2.95 - 3.25 mm0.1161 - 0.1280 in.
Ring Width-2nd Compression Ring3.45 - 3.75 mm0.1358 - 0.1476 in.
Ring Width-Oil Ring Pack2.30 - 2.60 mm0.0906 - 0.1024 in.
Ring Thickness-Top Compression Ring1.17 - 1.19 mm0.0461 - 0.0469 in.
Ring Thickness-2nd Compression Ring1.17 - 1.19 mm0.0461 - 0.0469 in.
Ring Thickness-Oil Ring Pack1.88 - 1.95 mm0.0740 - 0.0768 in.

PISTON RINGS

DESCRIPTIONSPECIFICATION
MetricStandard
Bearing Clearance0.032 - 0.060 mm0.0012 - 0.0023 in.
Wear Limit0.070 mm0.0027 in.
Bore Diameter-Piston Pin20.974 - 20.985 mm0.8257 - 0.8261 in.
Bore Diameter-Crankshaft End51 - 51.015 mm2.0078 - 2.0084 in.
Side Clearance0.1 - 0.25 mm0.0039 - 0.00098 in.
Wear Limit0.27 mm0.0106 in.
Weight-Total (Less Bearing)484 grams17.07 oz.

CONNECTING ROD

DESCRIPTIONSPECIFICATION
MetricStandard
Connecting Rod Journal Diameter
Journal Grade
147.966 - 47.972 mm1.8884 - 1.8886 in.
247.960 - 47.966 mm1.8884 - 1.8881 in.
347.954 - 47.960 mm1.8879 - 1.8881 in.
Rod Journal- Taper (Max)0.005 mm0.0001 in.
Main Bearing Journal Diameter
Journal Grade
051.985 - 51.988 mm2.0466 - 2.0467 in.
151.982 - 51.985 mm2.0465 - 2.0466 in.
251.979 - 51.982 mm2.0464 - 2.0465 in.
351.976 - 51.979 mm2.0462 - 2.0464 in.
451.973 - 51.976 mm2.0461 - 2.0462 in.
Journal Out-of-Round (Max.)0.005 mm0.0001 in.
Journal Taper (Max.)0.006 mm0.0002 in.
End Play0.05 - 0.25 mm0.0019 - 0.0098 in.
Wear Limit0.30 mm0.0118 in.
Main Bearing Diametrical Clearance0.028 - 0.048 mm0.0011 - 0.0018 in.
Main Bearing Diametrical Clearance (Max)0.058 mm0.0022 in.

CRANKSHAFT

DESCRIPTIONSPECIFICATION
MetricStandard
Cam Bearing Bore
Front Intake30.000 - 30.021 mm1.1810 - 1.1819 in.
Front Exhaust40.000 - 40.024 mm1.5747 - 1.5756 in.
Cam Bearing Bore No. 1-424.000 - 24.021 mm0.9448 - 0.9457 in.

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

DESCRIPTIONSPECIFICATION
MetricStandard
Cam Journal Diameter
Front Intake Cam29.964 - 29.980 mm1.1797 - 1.1803 in.
Front Exhaust Cam35.984 - 36.000 mm1.4166 - 1.4173 in.
Cam Journal Diameter No. 1-423.954 - 23.970 mm0.943 - 0.944 in.
Bearing Clearance - Diametrical
Front Intake Journal0.020 - 0.057 mm0.0008 - 0.0022 in.
Front Exhaust Journal0.019 - 0.051 mm0.0007 - 0.0020 in.
All Others0.020 - 0.067 mm0.0008 - 0.0026 in.
End Play0.11 - 0.25 mm0.004 - 0.009 in.
Max Lift @ 0.2 mm (0.007 in.) lash
Intake9.2 mm0.362 in.
Max Lift @ 0.28 mm (0.011 in.) lash
Exhaust8.42 mm0.331 in.
Intake Valve Timing w/ VVT in lock-pin position*
Closes (ABDC)49.3°
Opens (ATDC)10.3°
Duration219°
Exhaust Valve Timing w/ VVT in lock-pin position*
Closes (BTDC)8.45°
Opens (BBDC)45°
Duration216.55°
Valve Overlap @ 0.5 mm (0.019 in.) w/ VVT in lock-pin position18.75°
* All reading in crankshaft degrees at 0.5 mm (0.019 in.) valve lift.

CAMSHAFT

DESCRIPTIONSPECIFICATION
MetricStandard
MaterialCast Aluminum - Heat treated
Gasket Thickness (Compressed)0.54 mm0.021 in.
Valve Tappet Bore I.D.32.000 - 32.025 mm1.2598 - 1.2608 in.
Valve Tappet O.D.31.964 - 31.980 mm1.2584 - 1.2590 in.

CYLINDER HEAD

DESCRIPTIONSPECIFICATION
MetricStandard
Angle44.75° - 45.10°
Seat Outer Diameter - Intake34.45 - 34.61 mm1.3562 - 1.3625 in.
Seat Outer Diameter - Exhaust28.04 - 28.20 mm1.1039 - 1.1102 in.
Runout (Max.)0.05 mm0.002 in.
Valve Seat Width
Intake1.16 - 1.46 mm0.0456 - 0.0574 in.
Service Limit2.0 mm0.079 in.
Exhaust1.35 - 1.65 mm0.0531 - 0.0649 in.
Service Limit2.5 mm0.098 in.

VALVE SEAT

DESCRIPTIONSPECIFICATION
MetricStandard
Diameter I.D.5.500 - 5.518 mm0.2165 - 0.2172 in.
Guide Bore Diameter10.983 - 11.001 mm0.432 - 0.4331 in.
Guide Height (spring seat to guide tip)14.6 - 15.2 mm0.5748 - 0.5984 in.

VALVE GUIDE

DESCRIPTIONSPECIFICATION
MetricStandard
Face Angle - Intake and Exhaust45.25° - 45.75°
Head Diameter - Intake34.9 - 35.1 mm1.374 - 1.3818 in.
Head Diameter - Exhaust28.9 - 29.1 mm1.1377 - 1.1456 in.
Valve Lash
Intake0.17 - 0.23 mm0.006 - 0.009 in.
Exhaust0.27 - 0.33 mm0.010 - 0.012 in.
Valve Length (Overall)
Intake113.18 mm4.455 in.
Exhaust105.887 mm4.168 in.
Valve Stem Diameter
Intake5.465 - 5.480 mm0.2151 - 0.2157 in.
Exhaust5.458 - 5.470 mm0.2148 - 0.2153 in.

VALVES

DESCRIPTIONSPECIFICATION
MetricStandard
Intake0.672 mm0.0264 in.
Exhaust0.744 mm0.02929 in.

VALVE MARGIN

DESCRIPTIONSPECIFICATION
MetricStandard
Intake48.04 mm1.891 in.
Exhaust47.99 mm1.889 in.

VALVE STEM TIP

DESCRIPTIONSPECIFICATION
MetricStandard
Intake0.020 - 0.053 mm0.0008 - 0.0021 in.
Max. Allowable0.076 mm0.003 in.
Exhaust0.030 - 0.060 mm0.0012 - 0.0024 in.
Max. Allowable0.101 mm0.004 in.

VALVE STEM TO GUIDE CLEARANCE

DESCRIPTIONSPECIFICATION
MetricStandard
Free Length (Approx.)47.0 mm1.850 in.
Nominal Force (Valve Closed)179.5 N ± 9 @ 35.0 mm40.35 lbs. @ 1.38 in.
Nominal Force (Valve Open)364.8 N ± 17 N @ 29.25 mm82.01 lbs. ± 3.82 lbs. @ 1.152 in.
Installed Height35.00 mm1.378 in.
Number of Coils8.5 ± 0.1
Wire Diameter2.90 mm ± 0.030.114 in ± 0.001 in.

VALVE SPRINGS

DESCRIPTIONSPECIFICATION
MetricStandard
At Curb Idle Speed*25 kPa4 psi min.
At 3000 rpm170 - 550 kPa25 - 80 psi
CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm.
CAUTION
*If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm.

OIL PRESSURE

TORQUE SPECIFICATIONS

DESCRIPTIONN.mFt. Lbs.In. Lbs.
Balance Shaft ModuleRefer to INSTALLATION Procedure.
Bell Housing-Bolts4835
Camshaft Bearing Cap-Bolts
M6 Bolts12106
M8 Bolts3022
Coils871
Connecting Rod Cap-Bolts20 + 90°15 + 90°
Coolant Temperature Sender1813
Crankshaft Main Bearing Cap-BoltsRefer to INSTALLATION Procedure.
Crankshaft Damper-Bolt210155
Cylinder Head-BoltsRefer to INSTALLATION Procedure.
Cylinder Head Cover-BoltsRefer to INSTALLATION Procedure.
Engine Support Bracket-Bolts4030
Exhaust Manifold-Bolts3425
Exhaust Manifold Heat Shield-Bolts
M6 x 25 mm Bolts762
M6 x 70 mm Bolts980
Flex Plate to Crankshaft-Bolts29 + 51°22 + 51°
Intake Manifold-Bolts2418
Ladder Frame2216
Oil Cooler Connector Bolt4936
Oil Filter1410
Oil Filter Nipple4936
Oil Jet Fastener12106
Oil Pan-Bolts
M6 Bolts980
M8 Bolts2418
Oil Pan Drain-Plug4030
Oil Pressure Switch871
PCV Valve544
Phaser to Camshaft-Bolt5944
Spark Plugs2720239
Timing Chain Cover
M6 Bolts980
M8 Bolts2619
Timing Chain Tensioner Assembly-Bolts12106
Timing Chain Guides12106

Scheme 1

Scheme 1: ENGINE COVER
Scheme 1: ENGINE COVER
  1. Remove engine cover (1) by pulling upwards.

Scheme 2

Scheme 2: ENGINE ASSEMBLY
Scheme 2: ENGINE ASSEMBLY

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18
  1. Remove engine cover (1).
  2. Perform fuel pressure release procedure, then disconnect and remove fuel line (3). Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-485510-S12963059542012071300000) .
  3. Remove make-up air hose (2).
  4. Remove air cleaner housing assembly (1). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-485475-S36552825552012071300000) .
  5. Disconnect negative battery cable (1).
  6. Discharge air conditioning system, if equipped. Refer to «LINE, A/C DISCHARGE»(ref-485480-S15313089992012071300000) .
  7. Drain cooling system. Refer to «DRAINING»(ref-485484-S21678522742012071300000) .
  8. Remove coolant reservoir (1).
  9. Remove power steering reservoir (2).
  10. Remove power steering line support at engine mount (1).
  11. Remove power steering pump and set aside.
  12. Remove coolant hoses from coolant adapter (3).
  13. Disconnect coolant temperature sensor connector (1) and capacitor connector (2).
  14. Disconnect coils (1), injectors (4), cam sensors, oil temperature sensor, and oil control valve electrical connectors and reposition harness.
  15. Remove PCV hose (5) from valve cover.
  16. Remove harness from intake (2).
  17. Remove throttle body support bracket (1).
  18. Remove vacuum lines from throttle body and intake manifold.
  19. Disconnect electronic throttle control and manifold flow control valve electrical connectors.
  20. Remove dipstick.
  21. Remove intake bolts and remove intake.
  22. Disconnect coolant temperature sensor at block, knock sensor, oil pressure sensor, generator, starter, block heater (if equipped), A/C compressor (if equipped), and block ground.
  23. Remove accessory drive belt.
  24. Raise vehicle.
  25. Remove front splash shield.
  26. Drain oil (2).
  27. Remove exhaust pipe to exhaust manifold bolts (1).
  28. Disconnect oxygen sensor connector (3).
  29. Remove exhaust manifold heat shield (2).
  30. Remove exhaust manifold.
  31. Remove inspection cover (1) and mark torque converter to flywheel.
  32. On vehicles equipped with an automatic transaxle, remove torque converter bolts (1).
  33. On vehicles equipped with an manual transaxle, remove modular clutch bolts (1).
  34. Remove lower bellhousing bolts (2).
  35. Remove A/C compressor (1) from engine and set aside.
  36. Remove generator and lower idler pulley.
  37. Disconnect CKP sensor (2) electrical connector.
  38. Remove right engine mount bracket retaining bolts (4).
  39. Remove power steering hose hold down (3).
  40. Remove retaining nuts (2) and position mount bracket (1) aside.
  41. Remove intake oil control valve to prevent damage.
  42. Install engine lift chain to rear lift bracket and bolt to cylinder head (1) in the front.
  43. Hoist engine from vehicle.
  44. Separate engine and transmission.

Scheme 19

Scheme 19: ENGINE COVER
Scheme 19: ENGINE COVER
  1. Position engine cover (1) over mounting studs.
  2. Seat the cover on the rear studs by pushing downwards.
  3. Push downward on the front of the cover to seat the front studs.

Scheme 20

Scheme 20: ENGINE ASSEMBLY
Scheme 20: ENGINE ASSEMBLY

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34

Scheme 35

Scheme 35
Scheme 35

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37
  1. Connect engine lift chain (1) to engine.
  2. Slowly lower engine assembly in to position.
  3. Position right mount bracket (2) and install bolts (3).
  4. Install mounting bolts at the right engine mount bolts and tighten bolts to 118 N.m (87 ft. lbs.).
  5. Install through bolt (4) and tighten to 118 N.m (87 ft. lbs.).
  6. Install A/C compressor mounting bracket (2).
  7. Install A/C compressor (1) and connect lines.
  8. Install exhaust manifold and upper lower heat shields. Refer to «ENGINE/MANIFOLDS/EXHAUST MANIFOLD - INSTALLATION»(ref-485475-S02724143102012071300000) .
  9. Install oxygen sensor and connect electrical connector.
  10. Install Ground strap (1) near right strut tower.
  11. Raise vehicle.
  12. Install crankshaft position sensor (CKP) (2).
  13. Connect CKP electrical connector (2).
  14. Install manifold to exhaust pipe bolts (1) and tighten bolts.
  15. Install generator.
  16. Install lower bell housing bolts (2) and tighten.
  17. Align torque converter and flex plate mark. Install torque converter bolts (1) and tighten.
  18. Install inspection cover (1).
  19. Install new oil filter (1).
  20. Lower vehicle.
  21. Install upper idler pulley.
  22. Install power steering pump.
  23. Install power steering line support bracket (1).
  24. Install power steering pump.
  25. Install accessory drive belt.
  26. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, oil pressure sensor, generator, coolant temperature sensor at block, and block heater.
  27. Install intake manifold and tighten bolts to 24 N.m (18 ft. lbs.) as shown in illustration.
  28. Install throttle body support bracket (1).
  29. Connect manifold flow control valve and electronic throttle control electrical connectors.
  30. Insert wiring harness retainer into intake manifold (2).
  31. Install engine oil dip stick.
  32. Install PCV hose (5).
  33. Install vacuum lines at throttle body and intake manifold.
  34. Install intake air tube on throttle body.
  35. Connect engine harness electrical connectors.
  36. Install coolant hoses at coolant adapter (3).
  37. Install coolant reservoir (1) and connect hose.
  38. Connect fuel line to fuel rail (3).
  39. Connect negative battery cable (1).
  40. Install air cleaner housing (1) and connect inlet air hose. Refer to «ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION»(ref-485475-S16610754442012071300000) .
  41. Fill with coolant.
  42. 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.
  43. Evacuate the refrigerant system. Refer to «REFRIGERANT SYSTEM EVACUATE»(ref-485480-S26831705112012071300000) .
  44. Charge the refrigerant system. Refer to «REFRIGERANT SYSTEM CHARGE»(ref-485480-S14643213062012071300000) .
  45. Start engine and check for leaks.
  46. Install engine cover (1).

OIL FILTER SPECIFICATION

All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar® or the equivalent.

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