2.5L V6 Engine - VIN [H]: Other Dodge Stratus I

FUEL PRESSURE RELEASE

1. Disconnect fuel rail electrical harness from engine harness. Connect one end of a jumper wire to a 12-volt power source and other end to fuel rail harness terminal.
2. Using a second jumper, connect one end to a good ground. With other end of second jumper, momentarily ground one of injectors by connecting to an injector terminal in harness connector. Repeat procedure for 2 or 3 injectors.

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 65

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.

COOLING SYSTEM BLEEDING

Fill cooling system to 50 percent capacity with antifreeze. Then fill remainder of way with water. Thermostat will allow air to pass through it. Continue filling until full. Fill cooling reserve system to at least FULL HOT mark with a 50/50 mixture of coolant and water. It may be necessary to add additional coolant to reserve tank to maintain level between FULL HOT and ADD marks after several engine warm up cycles.

CYLINDER HEAD

Inspect cylinder head for signs of cracks and warpage. Repair or replace any cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. DO NOT grind more than .008" (.20 mm) combined total from surfaces of cylinder head and cylinder block deck.

Valve Springs

1. Valve springs are installed with enamelled end facing rocker arms. Inspect valve spring pressure and free length. Replace spring if it is not within specification. See «VALVES & VALVE SPRINGS»(ref-54219-S24149072352001011700000) table under ENGINE SPECIFICATIONS.
2. Measure valve spring installed height from spring seat to bottom of spring retainer. If spacers are installed, measure from top of spacer. If height exceeds 1.74" (44.2 mm), install a 0.030" (.762 mm) thick spacer in cylinder head counterbore to obtain correct installed height. See «VALVES & VALVE SPRINGS»(ref-54219-S24149072352001011700000) table under «ENGINE SPECIFICATIONS»(ref-54219-S11526018832001011700000) .

Valve Stem Oil Seals

Using Installer (MD998774), install Silver colored seals on intake guides and Black colored seals on exhaust guides.

Valve Guides

Check valve stem oil clearance. Ensure valve stem diameter is within specification See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Seat

Worn or burned valve seats can be reworked, provided proper angles and seat width are obtained.

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, and a 65-degree stone will raise valve seat.

Fitting Pistons

Note. Piston diameter should be measured at normal room temperature of 70°F (21°C).

To determine if piston-to-cylinder clearance is within specification, piston skirt diameter should be measured .080" (2 mm) from bottom of piston at 90-degree angle to piston pin. Piston diameter must be within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Cylinder bore measurements should be taken at approximately .50" (12.7 mm) below top surface of cylinder bore, middle of bore and approximately .50" (12.7 mm) from bottom of cylinder bore.

Piston Rings

Check ring end gap and side clearances. Check end gap with piston rings in bore at least.63" (16 mm) from bottom of piston bore. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Position ring gaps in proper locations. see scheme 22

Scheme 66

Rod Bearings

Before installing rod bearings, hold a straightedge across threads of connecting rod bolts. Ensure connecting rod bolt threads contact straightedge in all areas. If threads fail to contact straightedge, bolts are stretched and must be replaced. Apply a light coat of engine oil to connecting rod threads before tightening nut to specification. See TORQUE SPECIFICATIONS . Also see CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

Note. Crankshaft and main bearings size identification marks have changed after August 1995. See ENGINE TECHNICAL SERVICE BULLETIN No. 09-20-95.

1. Before installing main bearing main bearing cap, hold a straightedge across threads of main bearing cap bolts. Ensure main bearing cap bolt threads contact straightedge in all areas. If threads fail to contact straightedge, bolts are stretched and must be replaced.
2. Install upper main bearing shells, ensuring oil holes are in alignment and tabs are seated in block grooves.
3. Crankshaft thrust washers are installed at journal No. 3. Each pair of thrust washers has one washer with a locating tab and one without. One pair of thrust washers is installed in block and one pair is installed in main bearing cap. see scheme 23
4. Apply a thin film of grease to plain side of thrust washers and position them on each side of No. 3 main bearing in block (grooved surface toward crankshaft). Oil bearings and journals and install crankshaft.
5. Install lower main bearing shells (without oil grooves) in main bearing cap. Install remaining pair of thrust washers in main bearing cap. Carefully install main bearing cap with arrows toward timing belt end of engine. see scheme 23
6. Oil bearing cap bolt threads, and progressively tighten bolts to 69 ft. lbs. (94 N.m) in sequence. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-54219-S28913797252001011700000) for other specifications. see scheme 24

Scheme 67

Scheme 68

Cylinder Block

Note. Cylinder bore should be measured at normal room temperature of 70°F (21°C).

Check cylinder bore, out-of-round and taper. Measurements should be taken at approximately .50" (12.7 mm) below top surface of cylinder bore, middle of bore and approximately .50" (12.7 mm) from bottom of cylinder bore. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.

Oil Pressure

Oil pressure is 11 psi (.82 kg/cm 2 ) at idle and 35-75 psi (3-5 kg/cm 2 ) at 3000 RPM.