Dodge Caliber. Manual - part 1069

DESCRIPTION

SPECIFICATION

Metric

Standard

Piston Ring Groove Depth No. 3

4.108-4.220 mm

0.162-0.166 in.

PISTON RINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Ring Gap-Top Compression Ring

0.25-0.51 mm

0.0098-0.020 in.

Wear Limit

0.8 mm

0.031 in.

Ring Gap-2nd Compression Ring

0.23-0.48 mm

0.009-0.018 in.

Wear Limit

0.8 mm

0.031 in.

Ring Gap-Oil Control Steel Rails

0.25-0.64 mm

0.009-0.025 in.

Wear Limit

1.0 mm

0.039 in.

Ring Side Clearance-Compression
Rings

0.030-0.080 mm

0.0011-0.0031 in.

Wear Limit

0.10 mm

0.004 in.

Ring Side Clearance-Oil Ring Pack

0.012-0.178 mm

0.0004-0.0070 in.

Ring Width-Compression Rings

1.47-1.50 mm

0.057-0.059 in.

Ring Width-Oil Ring Pack

2.72–2.88 mm

0.107–0.1133 in.

CONNECTING ROD

DESCRIPTION

SPECIFICATION

Metric

Standard

Bearing Clearance

0.025–0.071 mm

0.0009–0.0027 in.

Wear Limit

0.075 mm

0.003 in.

Bore Diameter-Piston Pin

20.96–20.98 mm

0.8252–0.8260 in.

Bore Diameter-Crankshaft End

52.993-53.007 mm

2.0863-2.0868 in.

Side Clearance

0.13–0.38 mm

0.005–0.015 in.

Wear Limit

0.40 mm

0.016 in.

Weight-Total (Less Bearing)

565.8 grams

19.96 oz.

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Connecting Rod Journal Diameter

49.984 - 50.000 mm

1.968 - 1.9685 in.

Main Bearing Journal Diameter

59.992 - 60.008 mm

2.362 - 2.3625 in.

Journal Out-of-Round (Max.)

0.0035 mm

0.0003 in.

Journal Taper (Max.)

0.007 mm

0.0001 in.

PM

ENGINE 2.0L WORLD

9 - 1563

DESCRIPTION

SPECIFICATION

Metric

Standard

End Play

0.09 - 0.24 mm

0.0035 - 0.0094 in.

Wear Limit

0.38 mm

0.015 in.

Main Bearing Diametrical Clearance

0.018 - 0.062 mm

0.0007 - 0.0024 in.

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

DSECRIPTION

SPECIFICATION

Metric

Standard

Front Journal

Intake

30.000 - 30.021 mm

1.1810 - 1.1819 in.

Exhaust

40.000 - 40.021 mm

1.5747 - 1.5756 in.

Journals No. 1-4

24.000 - 24.021 mm

0.9448 - 0.9457 in.

CAMSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Journal Diameter No. 1

29.964 - 29.980 mm

1.179 - 1.180 in.

Journal Diameter No. 2-5

23.954 - 23.970 mm

0.943 - 0.944 in.

Bearing Clearance - Diametrical

0.030 - 0.067 mm

0.0011 - 0.0026 in.

End Play

0.11 - 0.25 mm

0.004 - 0.009 in.

Max Lift @ 0.2mm (0.007 in.) lash

Intake

9.2 mm

(0.362 in.)

Max Lift @ 0.28mm (0.011 in.) lash

Exhaust

8.42 mm

(0.331 mm)

Intake Valve Timing*

Closes (ABDC)

49.3°

Opens (ATDC)

10.3°

Duration

219°

Exhaust Valve Timing*

Closes (BTDC)

8.45°

Opens (BBDC)

45°

Duration

216.55°

Valve Overlap @ 0.5mm (0.019 in.)
w/ VVT in lock-pin position

18.75°

*
All reading in crankshaft degrees at 0.5 mm (0.019 in.) valve lift.

9 - 1564

ENGINE 2.0L WORLD

PM

CYLINDER HEAD

DESCRIPTION

SPECIFICATION

Metric

Standard

Material

Cast Aluminum - Heat treated

Gasket Thickness (Compressed)

0.54 mm

0.021 in.

VALVE SEAT

DESCRIPTION

SPECIFICATION

Metric

Standard

Angle

44.75° - 45.10°

Seat Diameter - Intake

34.45 - 34.61mm

1.3562 - 1.3625 in.

Seat Diameter - Exhaust

28.04 - 28.20 mm

1.1039 - 1.1102 in.

Runout (Max.)

0.05 mm

0.002 in.

Valve Seat Width

Intake

1.16 - 1.46 mm

0.0456 - 0.0574 in.

Exhaust

1.35 - 1.65 mm

0.0531 - 0.0649 in.

Service Limit - Intake

2.0 mm

0.079 in.

Service Limit - Exhaust

2.5 mm

0.098 in.

VALVE GUIDE

DESCRIPTION

SPECIFICATION

Metric

Standard

Diameter I.D.

5.500 - 5.512 mm

0.2165 -0.2170 in.

Guide Bore Diameter

10.983 - 11.001 mm

0.432 - 0.4331 in.

Guide Height (spring seat to guide
tip)

14.6 - 15.2 mm

0.5748 - 0.5984 in.

VALVES

DESCRIPTION

SPECIFICATION

Metric

Standard

Face Angle - Intake and Exhaust

45.25° - 45.75°

Head Diameter - Intake

34.9 - 35.1 mm

1.374 -1.3818 in.

Head Diameter - Exhaust

28.9 - 29.1 mm

1.1377 - 1.1456 in.

Valve Length (Overall)

Intake

112.76 - 113.32 mm

4.439 - 4.461 in.

Exhaust

110.89 - 111.69 mm

4.365 - 4.397 in.

Valve Stem Diameter

Intake

5.465 - 5.480 mm

0.2151 - 0.2157 in.

Exhaust

5.458 - 5.470 mm

0.2148 - 0.2153 in.

PM

ENGINE 2.0L WORLD

9 - 1565

VALVE MARGIN

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

0.672 mm

0.0264 in.

Service Limit

0.95 mm

0.0037 in.

Exhaust

0.744 mm

0.02929 in.

Service Limit

1.05 mm

0.039 in.

VALVE STEM TIP

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

48.04 mm

1.891 in.

Exhaust

47.99 mm

1.889 in.

VALVE STEM TO GUIDE CLEARANCE

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

0.048 - 0.066 mm

0.0018 - 0.0025 in.

Max. Allowable

0.076 mm

0.003 in.

Service Limit

0.25 mm

0.010 in.

Exhaust

0.0736 - 0.094 mm

0.0029 - 0.0037 in.

Max. Allowable

0.101 mm

0.004 in.

Service Limit

0.25 mm

0.010 in.

VALVE SPRINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Free Length (Approx.)

47.0 mm

1.850 in.

Nominal Force (Valve Closed)

179.5 N ± 9 @ 35.0 mm

40.35 lbs. @ 2.023 in.

Nominal Force (Valve Open)

364.8 N ± 17 N @ 29.25 mm

82.01 lbs. ± 3.82 lbs. @ 1.152 in.

Installed Height

35.00 mm

1.378 in.

Number of Coils

8.5 ± 0.1

Wire Diameter

2.90 mm ± 0.03

0.114 in ± 0.001 in.

OIL PRESSURE

DESCRIPTION

SPECIFICATION

Metric

Standard

At Curb Idle Speed*

25 kPa

4 psi

At 3000 rpm

170 - 550 kPa

25 - 80 psi

CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm.

9 - 1566

ENGINE 2.0L WORLD

PM