2.0L Engine - Service Information: Removal & Installation Dodge Caliber I

INSTALLATION

1. Install new filter element.
2. Place cover over air cleaner housing. Snap clasps (2) in place.
3. Install air inlet tube (5).
4. Connect intake air temperature sensor connector (4).
5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5).

REMOVAL

1. Remove fresh air inlet (2) from air cleaner housing (1).
2. Remove intake air temperature sensor electrical connector (4).
3. Remove air inlet tube (5) from housing (1).
4. Pull housing (1) upward to remove.

1. Make sure the rubber grommets, for the air cleaner housing lower pins, are in place when reinstalling the air cleaner housing. The rubber grommets mount to the PDC bracket.
2. Push air cleaner housing (1) down while aligning pins into the grommets.
3. Connect the throttle body air inlet hose (5) to the air cleaner housing (1).
4. Connect intake air temperature sensor connector (4).
5. Install fresh air inlet (2) and lock retainers (5).

1. Install phaser (2) assembly on camshaft. NOTE: Make sure the dowel is seated in the dowel hole and not in a oil feed hole. The dowel hole is larger than the 4 oil feed holes.
2. Install phaser retaining bolt and torque while holding camshaft in place with a wrench (1).
3. Install camshafts. Refer to «INSTALLATION»(ref-284945-S02384960962008051600000) .

1. Position mount (4) and torque bolts to 47 N.m (35 ft. lbs.).
2. Install fore aft member (3) and torque bolts to 100N.m (74 ft. lbs.).
3. Install mount through bolt (1) and torque to 47 N.m (35 ft. lbs.).
4. Lower vehicle.

Scheme 487

1. Remove rear mount retaining bolts (4).
2. Remove rear mount through bolt (1).
3. Remove oxygen sensor connector (2) from mount.
4. Remove rear mount (3).

1. Position rear mount (3).
2. Install rear mount retaining bolts (4) and torque to 50 N.m (37 ft. lbs.).
3. Install rear mount through bolt (1) and torque to 47 N.m (35 ft. lbs.).
4. Install oxygen sensor connector (2) retainer to mount (3).

Scheme 488

The lubrication system is a full-flow filtration, pressure feed type. The balance shaft module (BSM) is mounted below the ladder frame and chain driven by the crankshaft. The BSM consists of a non-serviceable pump, oil pressure relief valve, and a non-serviceable balance assembly.

Note. Not all engine blocks will be machined with the bolt on timing chain oil squirter. Some engines will be machined with an oil hole (1).

1. Lightly coat pressure regulating valve with clean engine oil and install valve (4).
2. Install spring (3) and cap (2).
3. Tighten cap to 44 N.m (32 lbs.ft.).

Scheme 489

The oil pump is integral to the balance shaft module (BSM) (2). The oil pump cannot be disassembled for inspection. The pressure relief valve is serviceable and can be removed and inspected. The BSM can be identified by the plastic end caps (1).

Scheme 490

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Scheme 492

1. Rotate engine to TDC (1,2) on #1 compression stroke.
2. Remove oil pan. Refer to «PAN-OIL»(ref-284945-S14124431562008051600000) .
3. Mark the chain (6) and the sprocket (5) for reassembly.
4. Push tensioner piston back into the tensioner body.
5. With piston held back insert tensioner pin 9703 (4) into the tensioner body to hold the piston in the retracted position. NOTE: Do not remove sprocket from BSM. CAUTION: There are two different length bolts used to attach the Balance Shaft Module (BSM) to engine block. The short bolt is 180 mm (7.086 in.) and the long bolt is 185 mm (7.283). The bolts must be replaced with the same length as removed or engine damage could result. CAUTION: Do not reuse the short bolt Balance Shaft Module (BSM) to engine block bolts. Always discard the short bolts is 180 mm (7.086 in.) bolts after removing. Failure to replace bolts can result in engine damage.
6. Remove BSM mounting bolts and discard.
7. Lower the back of the BSM and remove the chain (6) from the sprocket (5).
8. Remove BSM from the engine.

Scheme 493

Scheme 494

Scheme 495

1. Clean BSM mounting holes with Mopar® brake parts cleaner and compressed air.
2. Align marks on crankshaft sprocket (2) and chain (1).
3. Align marks on oil pump sprocket (5) and chain (4) with the mark on the balance shaft module.
4. Install chain on sprocket.
5. Pivot BSM assembly upwards and position on ladder frame.
6. Start new BSM mounting bolts by hand. NOTE: Use a three step procedure when torquing BSM mounting bolts.
7. Tighten BSM mounting bolts to 15 N.m (11 ft. lbs.) as shown.
8. Tighten BSM mounting bolts to 29 N.m (22 ft. lbs.) as shown.
9. Rotate bolts an additional 90° as shown.
10. Remove tensioner pin 9703 (4).
11. Install oil pan. Refer to «PAN-OIL»(ref-284945-S14124431562008051600000) .
12. Fill with oil.
13. Start engine and check for leaks.

Note. The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, the oil cooler should be replaced.

Scheme 496

Scheme 497

1. Raise vehicle on hoist.
2. Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-284880-S27432255532008051600000) .
3. Disconnect oil cooler coolant hoses.
4. Remove oil filter (3).
5. Remove oil cooler connector bolt (2).
6. Remove oil cooler (1).

Scheme 498

1. Replace oil cooler seal (1).
2. Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab.
3. Install oil cooler connector bolt (2). Tighten connector bolt to 55 N.m (41 ft. lbs.).
4. Install oil filter (3).
5. Connect oil cooler coolant hose.
6. Lower vehicle.
7. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-284880-S27432255532008051600000) .

Scheme 499

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Scheme 502

1. Remove engine cover (1).
2. Disconnect negative cable from battery.
3. Remove bolts attaching upper heat shield.
4. Remove upper heat shield.
5. Disconnect exhaust pipe from manifold.
6. Remove manifold support bracket (2).
7. Remove exhaust manifold heat shield (1).
8. Disconnect oxygen sensor electrical connector.
9. Remove exhaust manifold retaining fasteners.
10. Remove and discard manifold gasket.

Scheme 503

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Scheme 509

Scheme 510

1. Remove engine cover (1).
2. Perform fuel system pressure release procedure before attempting any repairs. Refer to «STANDARD PROCEDURE»(ref-284879-S20397598432008051600000) .
3. Remove air cleaner inlet (2).
4. Remove air cleaner housing (1).
5. Disconnect negative cable at battery (3).
6. Disconnect fuel line at rail (3).
7. Remove fuel injector electrical connectors (4).
8. Remove fuel rail retaining bolts and remove fuel rail.
9. Disconnect oil temperature sensor (1).
10. Disconnect variable valve timing solenoid electrical connector.
11. Disconnect intake camshaft position sensor electrical connector.
12. Position harness out of the way.
13. Remove throttle body support bracket (1).
14. Disconnect electronic throttle control electrical connector.
15. Remove wiring harness retainer from the intake manifold (2).
16. Disconnect MAP sensor electrical connector.
17. Disconnect vacuum lines at intake.
18. Remove upper radiator hose retaining bracket (1).
19. Remove intake manifold retaining bolts.
20. Remove intake manifold.