2.0L 4-CYL Engine - VIN [C]: Other Dodge Stratus I

FUEL PRESSURE RELEASE

1. Disconnect negative battery cable. Remove filler tank cap to release fuel tank pressure. Remove protective cap from fuel pressure test port on fuel rail. Fuel pressure test port is located at center of fuel rail.
2. Place open end of Fuel Pressure Gauge Hose (C-4799-1), into an approved container. Screw remaining end of fuel pressure gauge hose to fuel pressure test port. Fuel pressure will bleed off through hose into container.
3. After fuel pressure is released, remove fuel pressure gauge hose from fuel pressure test port. Reinstall protective cap on fuel pressure test port and fuel tank cap. Reinstall negative battery cable.

Fuel Lines

Fuel line clamps are not used on any fuel system component. If there is a fitting or line that needs repair it must be replaced. DO NOT use rubber hose and clamps to repair a fuel line.

Inspect all lines and quick connect fittings for leaks. Replace lines that rub against other vehicle components or show sign of wear. Ensure all lines are secured in their proper holders.

Quick-Connect Fittings

Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting contains non-serviceable O-ring seals.

Scheme 13

The quick-connect fitting consists of the O-rings, retainer and casing . When the fuel tube enters the fitting, the retainer locks the shoulder of the nipple in place and the O-rings seal the tube.

FUEL FILTER

The fuel filter mounts to the frame above the rear of the fuel tank. The inlet and outlet tubes are permanently attached to the filter.

Installtion

1. Place the new thermostat assembly into the engine outlet connector. Algin air bleed with notch on the cylinder head.
2. Install engine outlet connector onto cylinder head and tighten bolts to 12.5 N.m (110 in. lbs.). Connect the coolant recovery system (CRS) hose.
3. Fill cooling system. Refer to refilling System outlined in this section.

Installation - 2.5L Engine

Install thermostat into the recess in the thermostat housing. Install inlet elbow and tighten the bolts to 12 N.m (133 in. lbs.) (Scheme 16)

Cylinder Head

1. Inspect cylinder head for cracks and warpage. Repair or replace head if warpage exceeds specification. See «CYLINDER HEAD»(ref-54166-S19276536802001011700000) table under ENGINE SPECIFICATIONS.
2. After grinding valves or valve seats, install valve into cylinder head and measure distance from spring seat of cylinder head to tip of valve. Distance should be 1.889" (47.99 mm) for exhaust and 1.891" (48.04 mm) for intake. Grind valve tip and rechamfer as necessary.

Valve Springs

Measure valve spring free length, out-of-square and spring pressure. Measure installed height from valve spring lower edge to upper edge. DO NOT include spring seat or retainer flange. Replace valve spring if not within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

Ensure oversize valve stem seals are used when oversize valves are installed. Ensure oil seal lower edge is against valve guide after installation.

Valve Guide

1. Check valve stem oil clearance. Ensure valve stem diameter is within specification. See «VALVES & VALVE SPRINGS»(ref-54166-S35181812732001011700000) table under ENGINE SPECIFICATIONS. Ream valve guide for valve with oversize valve stem if clearance exceeds specification. See «CYLINDER HEAD»(ref-54166-S19276536802001011700000) table under ENGINE SPECIFICATIONS. NOTE: DO NOT ream valve guides from standard to maximum in one step. Ream guides to oversize in gradual steps, so guides are reamed true in relation to valve seat.
2. Valves are available with oversize valve stems of .006" (.15 mm), .016" (.40 mm) and .031" (.80 mm). Replace guides if they cannot be repaired using a .031" (.80 mm) oversize reamer.

Valve Seat

If valve face and/or valve seat has been ground, measure valve tip to valve spring seat dimension. Grind valve tip (if necessary) to give an installed height for exhaust valves of 1.889" (47.99 mm) and 1.891 (48.04) for intake valves.

Valves

After grinding valves, inspect remaining margin. Intake valves with less than .045" (1.15 mm) margin and exhaust valves with less than .058" (1.48 mm) margin should be replaced.

Valve Seat Correction Angles

If seat width is too wide after grinding, use a 15-degree or 65-degree stone to alter seat width. A 15-degree stone will lower valve seat. A 65-degree stone will raise valve seat. For valve seat width, see CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Fitting Pistons

1. To determine if piston-to-cylinder clearance is within specification, measure piston skirt diameter .688" (17.5 mm) from bottom of piston skirt, at 90-degree angle to piston pin. Ensure piston diameter is within specification. See «PISTONS, PINS & RINGS»(ref-54166-S06883982842001011700000) table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore .394" (10.0 mm) below top of cylinder bore, at middle of bore and .394" (10.0 mm) from bottom of cylinder bore.

Piston Rings

Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Position ring gaps in proper locations before installing rings. see scheme 15

Scheme 14

Rod Bearings

Note direction of connecting rod and cap installation before removing. Install connecting rod in original direction.

Crankshaft & Main Bearings

1. Ensure crankshaft end play is within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD»(ref-54166-S21885220042001011700000) table under ENGINE SPECIFICATIONS. Install main bearing shells with oil holes aligned with oil holes in block and tabs seated in block tab slots. CAUTION: DO NOT allow oil on bedplate mating surface. Oil will adversely effect ability of sealer to seal bedplate to cylinder block.
2. Using fresh, clean oil, lubricate bearings and crankshaft journals and install crankshaft. Apply.059-.078" (1.5-2 mm) bead of Anaerobic Sealer (4773257) to cylinder block. see scheme 16 CAUTION: Use only Anaerobic Sealer (4773257) on bedplate or damage may occur to engine.
3. Install lower main bearings into main bearing cap/bedplate. Ensure bearing tabs are seated into bedplate slots. Install main bearing cap/bedplate onto engine.
4. Clean and oil main bearing bolts before installation. Install main bearing bolts No. 11, 17 and 20 finger tight. Tighten these bolts together until bedplate contacts cylinder block uniformly. Tighten bolts No. 11, 17 and 20 to 22 ft. lbs. (30 N.m). see scheme 17
5. Install main bearing bolts No. 1-10 and tighten in sequence to 60 ft. lbs. (81 N.m). Install main bearing bolts No. 11-20 and tighten in sequence to 22 ft. lbs. (30 N.m). see scheme 17 After main bearing bedplate is installed, check crankshaft turning torque. Turning torque should not exceed 50 INCH lbs. (5.6 N.m).

Scheme 15

Scheme 16

Cylinder Block

1. Measure cylinder bore .394" (10.0 mm) below top of cylinder bore, at middle of bore and .394" (10.0 mm) from bottom of cylinder bore.
2. Check cylinder block deck surface warpage. Resurface cylinder block if warpage exceeds specification. See «CYLINDER BLOCK»(ref-54166-S38769155382001011700000) table under ENGINE SPECIFICATIONS. DO NOT grind more than .008" (.20 mm) total from surface of cylinder head and deck surface of cylinder block.

Oil Pressure

Oil pressure is 4 psi (.28 kg/cm 2 ) at curb idle and 25-80 psi (1.75-5.62 kg/cm 2 ) at 3000 RPM.

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS

CONNECTING RODS

PISTONS, PINS & RINGS

PISTONS, PINS & RINGS

CYLINDER BLOCK

VALVES & VALVE SPRINGS

VALVES & VALVE SPRINGS

CYLINDER HEAD

CAMSHAFT

CAMSHAFT