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

INSTALLATION

1. Make sure the rubber grommets, for the air cleaner body lower pins, are in place when reinstalling the air cleaner body.
2. Push down on the air cleaner body (1) to engage the pins into the grommets.
3. Install the support bracket bolt to the strut tower and tighten to 10 N.m (89 in. lbs.).
4. Install the air inlet tube (2) to the air cleaner body (1).
5. Connect the make-up air hose (3) to the air cleaner body.
6. Position the PCM (4) on the air cleaner body cover.
7. Install three mounting bolts (3) with one ground wire (1) and tighten to 10 N.m (89 in. lbs.).
8. Install the fresh air inlet duct (3) on the air cleaner body (1) and lock the retainers (2).

REMOVAL

Note. Camshaft phaser and camshaft sprocket are supplied as an assembly, do not attempt to disassemble.

Scheme 158

1. Remove camshafts. Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-484035-S10049768032012070400000) .
2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in place with a wrench (1) on the camshaft flats.
3. Remove phaser (2) assembly from camshaft.

1. Install phaser (2) assembly on camshaft. NOTE: Make sure the dowel is seated in the dowel hole and not in an oil feed hole. The dowel hole is larger than the 4 oil feed holes.
2. Install phaser retaining bolt. Hold camshaft in place with a wrench (1) and tighten bolt to 59 N.m (44 ft. lbs.).
3. Install camshafts. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-484035-S12300485822012070400000) .

1. Install flex plate (1).
2. Install washer (2).
3. Install new flex plate bolts (3) and tighten in a criss-cross pattern to 29 N.m (22 ft. lbs.) plus 51° rotation.
4. Install transaxle. Refer to «INSTALLATION»(ref-484055-S04527390072012070400000) , «INSTALLATION»(ref-484056-S15565509602012070400000) or «INSTALLATION»(ref-484063-S34980059192012070400000) .

Scheme 159

Scheme 160

1. Remove oil pan. Refer to «PAN, OIL, REMOVAL»(ref-484035-S18380794452012070400000) .
2. Remove balance shaft assembly. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-484035-S25751542902012070400000) .
3. Remove ladder frame retaining bolts.
4. Remove ladder frame using pry point cast in the rear of the block (1).
5. To assist in removing the ladder frame another (1) pry point cast in the right side of the block.

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 161

1. Raise vehicle.
2. Remove fore aft member (3) to mount (4) bolts.
3. Remove mount through bolt (1).
4. Remove fore aft member (3) mounting bolts and remove.
5. Remove front mount (4).

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

Scheme 162

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Scheme 164

1. Remove air cleaner inlet (2) and air cleaner housing (1).
2. Remove PCM (1).
3. Remove PCM mounting bracket.
4. Disconnect negative cable from battery (3).
5. Support transaxle with a suitable jack.
6. Remove left mount through bolt (3).
7. Remove left mount bracket to body frame rail fasteners (1).
8. Remove mount.

Scheme 165

Scheme 166

Scheme 167

1. Position mount (2) in place.
2. Install left mount to frame rail bolts (1) and torque to 75 N.m (55 ft. lbs.).
3. Install mount through bolt (3) and torque to 100 N.m (74 ft. lbs.).
4. Remove jack.
5. Install PCM mounting bracket.
6. Install PCM (1).
7. Connect negative cable to battery (3).
8. Install air cleaner housing (1) and air cleaner inlet (2).

Scheme 168

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Scheme 170

1. Remove coolant reservoir (3) and set aside.
2. Remove power steering reservoir (2) and set aside.
3. Remove windshield washer bottle (1).
4. Remove power steering line support bracket (1) from engine mount.
5. Support transaxle with a block of wood and a suitable jack.
6. Remove engine mount through bolt (4).
7. Remove engine mount bracket bolts (3).
8. Remove engine mount retaining bolts.
9. Remove engine mount.

Scheme 171

Scheme 172

Scheme 173

1. Position right engine mount (1).
2. Install engine mount retaining bolts and tighten to 75 N.m (55 ft. lbs.).
3. Install engine mount adapter (2) and tighten bolts (3) to 68 N.m (50 ft. lbs.).
4. Install engine mount through bolt (4) and tighten to 88 N.m (65 ft. lbs.).
5. Remove jack.
6. Install power steering line support bracket (1) at engine mount.
7. Install windshield washer bottle (1).
8. Install power steering reservoir (2).
9. Install coolant reservoir (3).
10. Install engine cover.

Scheme 174

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.

Scheme 175

Note. Not all blocks have the bolt on timing chain oil squirter. Engine blocks either have a bolt-on oil squirter or a 1.0 mm hole (1) drilled into the oil gallery passage. Engine blocks with the 1.0 mm hole no longer use an oil squirter even though the threaded mounting hole may still be present.

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 176

Scheme 177

1. Raise vehicle on hoist.
2. Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-484045-S38134051662012070400000) .
3. Disconnect oil cooler coolant hoses.
4. Remove oil filter (3).
5. Remove oil cooler connector bolt (2).
6. Remove oil cooler (1).

Scheme 178

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-484045-S38134051662012070400000) .

Scheme 179

1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove.

Scheme 180

1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of gasket.
2. Lubricate new oil filter gasket.
3. Screw oil filter (1) on until the gasket contacts base. Tighten to 14 N.m (11 ft. lbs.).

Note. Rear plug shown in illustration, other plugs are similar.

1. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean the block.
2. Install the plug (2) flush with the block boss face (1). The plug (2) is correctly installed when it is flush or protruding no more than 1 mm from the block boss face (1).

Scheme 181

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 182

Scheme 183

Scheme 184

Scheme 185

1. Rotate engine to TDC (1, 2) on #1 compression stroke.
2. Remove the oil pan. Refer to «PAN, OIL, REMOVAL»(ref-484035-S18380794452012070400000) .
3. Remove the engine timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-484035-S14706329202012070400000) .
4. Mark the chain (6) and the sprocket (5) for reassembly.
5. Push tensioner piston back into the tensioner body.
6. With piston held back insert tensioner pin (special tool #9703, Pin, Tensioner) (4) into the tensioner body to hold the piston in the retracted position. NOTE: Do not remove sprocket from BSM.
7. Remove BSM mounting bolts. Discard 180 mm bolts, 185 mm bolts can be reused.
8. Lower the back of the BSM and remove the chain (6) from the sprocket (5).
9. Remove BSM from the engine.

Scheme 186

1. Remove timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-484035-S14706329202012070400000) .
2. Remove oil pan. Refer to «PAN, OIL, REMOVAL»(ref-484035-S18380794452012070400000) .
3. Measure the distance between the tensioner body and the guide shoe as shown in illustration.
4. If the distance is 10.1 mm (0.397 in.) or greater, replace the chain.

Scheme 187

Scheme 188

1. The 185 mm (7.283 in.) length bolts must be checked for stretching. Check the bolts with a straight edge for necking (2). If the bolts are necked down, they must be replaced.
2. Clean BSM mounting holes with Mopar® brake parts cleaner.
3. If chain was removed, align marks on crankshaft sprocket (2) and chain (1).
4. Align marks on oil pump sprocket (5) and chain (4).
5. Install chain on sprocket.
6. Pivot BSM assembly upwards and position on ladder frame.
7. Start BSM mounting bolts by hand. NOTE: Use a three step procedure when tightening BSM mounting bolts. For new 180 mm bolts, go to step 8 . For 185 mm bolts, go to step 9 .
8. Tighten new 180 mm BSM mounting bolts as follows: Tighten to 15 N.m (11 ft. lbs.) in the sequence shown in illustration. Tighten to 33 N.m (24 ft. lbs.) in the sequence shown in illustration. Rotate bolts an additional 90° in the sequence shown in illustration.
9. Tighten 185 mm BSM mounting bolts as follows: Tighten to 15 N.m (11 ft. lbs.) in the sequence shown in illustration. Tighten to 29 N.m (22 ft. lbs.) in the sequence shown in illustration. Rotate bolts an additional 90° in the sequence shown in illustration.
10. Remove tensioner pin (special tool #9703, Pin, Tensioner) (4).
11. Install the engine timing cover. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-484035-S18459513662012070400000) .
12. Install the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-484035-S20678553562012070400000) .
13. Fill engine with oil.
14. Start engine and check for leaks.

Scheme 189

1. Disconnect oil temperature sensor (1) electrical connector.
2. Remove sensor (1).

Scheme 190

1. If re-using the oil temperature sensor, coat the threads with Mopar® thread sealant.
2. Install oil temperature sensor (1). Tighten to 8 N.m (71 in. lbs.).
3. Connect electrical connector.

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 191

Scheme 192

Scheme 193

Scheme 194

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 195

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Scheme 200

1. Remove engine cover (1).
2. Perform fuel system pressure release procedure before attempting any repairs. Refer to «FUEL SYSTEM PRESSURE RELEASE PROCEDURE»(ref-484044-S14857747832012070400000) .
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.