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2.0L Engine - Service Information: Specifications Dodge Caliber I

Mechanical 18 illustrations ~108 words

TORQUE

DESCRIPTIONN.mFt. Lbs.In. Lbs.
Balance Shaft Module29 + 90°22 + 90°
Bell Housing4835
Camshaft Sprocket-Bolt6044
Camshaft Bearing Cap-Bolts
M6 Bolts12105
M8 Bolts3425
Connecting Rod Cap-Bolts20 +90°15 +90°
Coolant temperature Sender871
Crankshaft Main Bearing Cap-Bolts27 + 45°20 + 45°
Crankshaft Damper-Bolt210155
Cylinder Head-BoltsRefer to Procedure
Cylinder Head Cover-Bolts1090
Engine Support Bracket-Bolts4030
Exhaust Manifold-Bolts3425
Exhaust Manifold Heat Shield-Bolts980
Flex Plate to Crankshaft-Bolts9570
Intake Manifold2418
Ladder Frame2216
Oil Cooler Connector Bolt4936
Oil Filter1410
Oil Filter Nipple4936
Oil Jet Fastener12105
Oil Pan-Bolts
M6 Bolts9.585
M8 Bolts2518220
Oil Pan Drain-Plug4030
Oil Pressure Switch871
PCV Valve540
Spark Plugs2720239
Timing Chain Cover
M6 Bolts980
M8 Bolts26230
Timing Chain Tensioner Assembly-Bolts12 N.m105
Timing Chain Guides12 N.m105

TORQUE SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
TypeIn-Line OHV, DOHC
Number of Cylinders4
Firing Order1-3-4-2
Compression Ratio10.5:1
Max. Variation Between Cylinders25%
Displacement2.0 Liters122 cu. in.
Bore86 mm3.386 in.
Stroke86 mm3.386 in.
Compression Pressure1172-1551 kPa170-225 psi

GENERAL SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
MaterialCast Aluminum
Cylinder Bore Diameter
A86.0 < 86.0103.3858 < 3.3862 in.
B86.010 < 86.0203.3862 < 3.3866 in.
C86.020 < 86.0303.3866 < 3.3869 in.
Cylinder Bore Out-of-Round (Max.)0.020 mm0.0008 in.
Cylinder Bore 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.
Weight345 - 355 grams12.17 - 12.52 oz.
Land Clearance (Diametrical)0.60 - 0.73 mm0.0236 - 0.0287 in.
Piston Length49.0 mm2.929 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 mm0.001 - 0.002 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 - 0.0098 in.
Wear Limit0.27 mm0.0106 in.
Weight-Total (Less Bearing)490 grams17.28 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
Front Cam Bearing Bore
Intake30.000 - 30.021 mm1.1810 - 1.1819 in.
Exhaust40.000 - 40.024 mm1.5747 - 1.5757 in.
Cam Bearing Bore No. 1-424.000 - 24.021 mm0.9448 - 0.9457 in.

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

DESCRIPTIONSPECIFICATION
MetricStandard
Front Cam Journal Diameter
Intake Cam31.984 - 32.000 mm1.2592 - 1.2598 in.
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 Exhaust Journal0.019-0.051 mm0.0007-0.0020 in.
All Others0.030 - 0.067 mm0.0011 - 0.0026 in.
End Play0.11 - 0.25 mm0.004 - 0.009 in.
Max Lift @ 0.2mm (0.007 in.) lash
Intake9.2 mm(0.362 in.)
Max Lift @ 0.28mm (0.011 in.) lash
Exhaust8.42 mm(0.331 mm)
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.

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.
Exhaust1.35 - 1.65 mm0.0531 - 0.0649 in.
Service Limit - Intake2.0 mm0.079 in.
Service Limit - Exhaust2.5 mm0.098 in.

VALVE SEAT

DESCRIPTIONSPECIFICATION
MetricStandard
Diameter I.D.5.500 - 5.512 mm0.2165 - 0.2170 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 - 0.12 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
Intake0.048 - 0.066 mm0.0018 - 0.0025 in.
Max. Allowable0.076 mm0.003 in.
Service Limit0.25 mm0.010 in.
Exhaust0.0736 - 0.094 mm0.0029 - 0.0037 in.
Max. Allowable0.101 mm0.004 in.
Service Limit0.25 mm0.010 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. @ 2.023 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

Scheme 343

Scheme 343: WORLD ENGINE
Scheme 343: WORLD ENGINE

Scheme 344

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Scheme 360
Scheme 360

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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