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PRODUKT NIEDOSTĘPNY
Indeks towaru: SILNIK 2,4 Turbo
Realizacja zamówienia: 24

WYMIANA USZCZELKI GŁOWICY

Labor Operations: Click to display a list of Labor Operations associated with this procedure

CAUTION: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

1. Check cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.





NOTE: Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged.

CAUTION: Always replace the variable valve timing filter screen (3) when servicing the head gasket or engine damage could result.

2. Replace the variable valve timing filter screen (3).



NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil.

NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes.

3. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder block as shown.



4. Position the new cylinder head gasket on engine block with the part number facing up. Ensure gasket is seated over the locating dowels in block.

5. Place two pea size dots of Mopar® engine sealant RTV or equivalent (1) on cylinder head gasket as shown.

NOTE: The head must be installed within 15 minutes before the RTV skins.

6. Position cylinder head onto engine block.



CAUTION: This engine was built with 2 different style cylinder head bolts. Each style bolt requires a different torque value. The bolts can be identified by the short bolt head (1) and the long bolt head (2).

7. Measure the bolt head from the washer to the top of the bolt head. The short bolt head (1) measures 8 mm (5/16”) and the long bolt head (2) measures 13 mm (1/2”).

8. Identify whether your engine has the short head design (1) or the long head design (2).



NOTE: The front two cylinder head bolts do not have captured washers. The washers must be installed with the bevel edge (1) up towards the bolt head.



9. Install washers (1) for the front two cylinder head bolts with the beveled edge facing up.



NOTE: Before installing the cylinder head bolts, lubricate the threads with clean engine oil.

10. Install the cylinder head bolts and tighten in the sequence shown.



11. If your bolt has the short head (1), use the following torque specifications:

  1. First: All to 30 N·m (25 ft. lbs.)
  2. Second: All to 61 N·m (45 ft. lbs.)
  3. Third: All to 61 N·m (45 ft. lbs.)
  4. Fourth: All an additional 90°CAUTION:Do not use a torque wrench for the Fourth step.

12. If your bolt has the long head (2), use the following torque specifications:

  1. First: All to 30 N·m (25 ft. lbs.)
  2. Second: All to 73 N·m (54 ft. lbs.)
  3. Third: All to 73 N·m (54 ft. lbs.)
  4. Fourth: All an additional 90°CAUTION:Do not use a torque wrench for the Fourth step.

13. Clean excess RTV from timing chain cover sealing surface.



14. Install coolant adapter (3) with new seals. Tighten bolts to 18.1 N·m (159 in. lbs.).



15. The front camshaft bearing cap (1) is numbered (2) either one, two, or three, this corresponds to the select fit front exhaust camshaft bearing to use.



16. Install the corresponding select fit front exhaust camshaft bearing (1).

17. Oil all of the camshaft journals with clean engine oil.



18. Position exhaust camshaft (1) and intake camshaft (2) on bearing journals in the cylinder head.

19. Align camshaft timing marks (3) so that they are facing each other and are in line with the cylinder head cover sealing surface.

CAUTION: Install the front intake and exhaust camshaft bearing cap last. Ensure that the dowels are seated and follow torque sequence or damage to engine could result.

NOTE: If the front camshaft bearing cap is broken, the cylinder head MUST be replaced.

20. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 9.5 N·m (85 in. lbs.) in the sequence shown.



NOTE: Verify that the exhaust bearing shells are correctly installed, and the dowels are seated in the head, prior to torquing bolts.

21. Install the front intake and exhaust bearing cap and tighten bolts to 25 N·m (18 ft. lbs.) in the sequence shown.



22. Install timing chain guide (4) and tighten bolts to 12 N·m (105 in. lbs.).

23. Install the moveable timing chain pivot guide (6) and tighten bolt to 12 N·m (105 in. lbs.).

24. Install timing chain (2) and tensioner (5) 

25. Install timing chain cover, engine mount, pulleys and accessory drive belt



26. Install cylinder head cover and ignition coils



27. Install exhaust manifold

28. Install ground strap (1) at right rear of cylinder head if equipped.



29. Install intake manifold, vacuum lines and fuel rail



30. Install upper radiator hose retaining bracket bolt (1).



31. Connect coil (1) and injector (4) electrical connectors.



32. Connect electrical connectors to coolant temperature sensor (1), camshaft position sensors, oil temperature sensor, variable valve timing solenoids, MAP sensor, manifold tuning valve, ignition interference suppressor (2) and electronic throttle control.



33. Install power steering pump reservoir (2). Tighten mounting screw to 12 N·m (106 in. lbs.).

34. Install windshield washer reservoir (1).

35. Install coolant recovery reservoir (3). Tighten mounting bolts to 4 N·m (35 in. lbs.).



36. Install clean air hose (5) and air cleaner housing (1)

37. Fill cooling system

38. Install new oil filter and fill engine with oil.

39. Connect negative battery cable.



40. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for leaks and correct fluid levels.

41. Install engine cover (1).

 

 

 

 

 

 

 TABELA WARTOŚCI MOMENTÓW DOKRĘCANIA

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.
Balance Shaft Module Refer to Procedure
Bell Housing-Bolts 48 35 -
Camshaft Bearing Cap-Bolts      
M6 Bolts 12 - 106
M8 Bolts 30 22 -
Coils 8 - 71
Connecting Rod Cap-Bolts      
  20 + 90° 15 + 90° -
Turbo 25 + 90° 18 + 90° -
Coolant Temperature Sender 18 13 -
Crankshaft Main Bearing Cap-Bolts Refer to Procedure
Crankshaft Damper-Bolt 210 155 -
Cylinder Head-Bolts Refer to Procedure
Cylinder Head Cover-Bolts Refer to Procedure
Engine Support Bracket-Bolts 40 30 -
Exhaust Manifold/Turbocharger to Cylinder Head-Bolts 34 25 -
Exhaust Manifold Heat Shield-Bolts      
M6x25mm Bolts 7 - 62
M6x70mm Bolts 9 - 80
Turbo 17 - 150
Flex Plate to Crankshaft-Bolts 29 + 51° 22 + 51° -
Flywheel to Crankshaft-Bolts (SRT4) 133 98 -
Intake Manifold-Bolts 24 18 -
Ladder Frame 22 16 -
Oil Cooler Connector Bolt 49 36 -
Oil Filter Refer to Procedure Refer to Procedure -
Oil Filter Nipple 49 36 -
Oil Jet Fastener 12 - 106
Oil Pan-Bolts      
M6 Bolts 9 - 80
M8 Bolts 24 18 -
Oil Pan Drain-Plug 40 30 -
Oil Pressure Switch 8 - 71
PCV Valve 5 - 44
Phaser to Camshaft-Bolt 59 44 -
       
       
Spark Plugs 27 20 239
Timing Chain Cover      
M6 Bolts 9 - 80
M8 Bolts 26 19 -
Timing Chain Tensioner Assembly-Bolts 12 - 106
Timing Chain Guides 12 - 106
Fastener, Charge Air Cooler 8 - 71
Hose Clamps, Charge Air Cooler 1.7 - 15
Banjo Fitting, Turbocharger Coolant Line 40 30 -
Brass Fitting Turbocharger Coolant/Oil Line-to-Block 31 23 -
Steel Flared Fitting, Turbocharger Coolant/Oil-to-Block 31 23 -
Elbow Support Bracket 55 41 -
Fastener, Thurbocharger Heat Shield 17 - 150
Fastener, Turbocharger Oil Return Tube-to-Turbocharger 12 - 105
Turbocharger Support Bracket 54 40 -
Turbocharger-to-Exhaust Manifold Bracket 12 - 105
Brass Fitting-Turbocharger Oil Line 41 30 -
Fasteners, Turbocharger-to-Exhaust Manifold 28 21 -
Clip, Coolant Supply Line-to-Turbocharger 5 - 45
NUTS, Catalytic Converter-to-Turbocharger 26 - 240

 

2.4L TURBO ENGINE GENERAL SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Metric

Standard
Type In-Line OHV, DOHC
Number of Cylinders 4
Firing Order 1-3-4-2
Compression Ratio 8.6:1
Displacement 2.4 Liters 146.5 cu. in.
Bore 88 mm 3.465 in.
Stroke 97 mm 3.819 in.
Compression Pressure 896 - 1310 Kp 130 - 190 psi
Max. Variation Between Cylinders 25%

CYLINDER BLOCK

DESCRIPTION

SPECIFICATION

Metric

Standard
Material Cast Aluminum
Cylinder Bore Diameter
A 88.000 - 88.010 mm 3.4645 - 3.4649 in.
B 88.010 - 88.020 mm 3.4649 - 3.4653 in.
C 88.020 - 88.030 mm 3.4653 - 3.4657 in.
Cylinder Bore Out-of-Round (Max.) 0.020 mm 0.0008 in.
Cylinder Bore Diameter Taper (Max.) 0.028 mm 0.001 in.
Main Bearing Bore Diameter
1 56.000 - 56.006 mm 2.2047 - 2.2049 in.
2 56.006 - 56.012 mm 2.2049 - 2.2051 in.
3 56.012 - 56.018 mm 2.2051 - 2.2054 in.
Main Bearing Bore Diameter Taper (Max.) 0.0082 mm 0.0003 in.

PISTONS

DESCRIPTION

SPECIFICATION

Metric

Standard
Piston Diameter
A 87.970 - 88.000 mm 3.4634 - 3.4646 in.
B 87.980 - 88.010 mm 3.4638 - 3.4650 in.
C 87.990 - 88.020 mm 3.4642 - 3.4654 in.
Clearance to Bore 0.000 - 0.040 mm 0.000 - 0.0016 in.
Weight 337.8 - 345.8 grams 11.92 - 12.20 oz.
Land Clearance (Diametrical) 0.559 - 0.700 mm 0.0220 - 0.0276 in.
Piston Length 50.5 mm 1.988 in.
Piston Ring Groove Depth No. 1 3.93 - 4.09 mm 0.1548 - 0.1611 in.
Piston Ring Groove Depth No. 2 3.93 - 4.06 mm 0.1548 - 0.1600 in.
Piston Ring Groove Depth No. 3 2.85 - 3.05 mm 0.1123 - 0.1200 in.

PISTON PINS

DESCRIPTION

SPECIFICATION

Metric

Standard
Clearance in Piston 0.004 - 0.014 mm 0.0002 - 0.0006 in.
Clearance in Connecting Rod 0 - 0.023 mm 0 - 0.0009 in.
Diameter 21.997 - 22.000 mm 0.8660 - 0.8661 in.
End Play 0.54 - 1.56 mm 0.021 - 0.061 in.
Length 59.28 - 59.72 mm 2.334 - 2.351 in.

PISTON RINGS

DESCRIPTION

SPECIFICATION

Metric

Standard
Ring Gap-Top Compression Ring 0.20 - 0.35 mm 0.0079 - 0.0138 in.
Wear Limit 0.8 mm 0.031 in.
Ring Gap-2nd Compression Ring 0.50 - 0.70 mm 0.0197 - 0.0276 in.
Wear Limit 0.8 mm 0.031 in.
Ring Gap-Oil Control Steel Rails 0.15 - 0.60 mm 0.0059 - 0.0236 in.
Wear Limit 1.0 mm 0.039 in.
Ring Side Clearance-Compression Rings 0.035 - 0.08 mm 0.0014 - 0.0031 in.
Wear Limit 0.1 mm 0.004 in.
Ring Side Clearance-Oil Ring Pack 0.05 - 0.19 mm 0.0020 - 0.0075 in.
Ring Width-Top Compression Ring 2.99 - 3.29 mm 0.1177 - 0.1295 in.
Ring Width-2nd Compression Ring 3.23 - 3.48 mm 0.1272 - 0.1370 in.
Ring Width-Oil Ring Pack 2.45 - 2.65 mm 0.0965 - 0.1043 in.
Ring Thickness-Top Compression Ring 1.175 - 1.19 mm 0.0463 - 0.0469 in.
Ring Thickness-2nd Compression Ring 1.475 - 1.49 mm 0.0581 - 0.0587 in.
Ring Thickness-Oil Ring Pack 1.86 - 1.98 mm 0.0732 - 0.0780 in.

CONNECTING ROD

DESCRIPTION

SPECIFICATION

Metric

Standard
Bearing Clearance 0.032 - 0.060 mm 0.0012 - 0.0023 in.
Wear Limit 0.070 mm 0.0027 in.
Bore Diameter-Piston Pin 22.016 - 22.024 mm 0.86687 - 0.8671 in.
Bore Diameter-Crankshaft End 51.003 - 51.015 mm 2.0080 - 2.0085 in.
Side Clearance 0.1 - 0.25 mm 0.0039 - 0.00098 in.
Wear Limit 0.27 mm 0.0106 in.
Weight-Total (Less Bearing) 571 grams 20.14 oz.

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard
Connecting Rod Journal Diameter
Journal Grade
1 47.966 - 47.972 mm 1.8884 - 1.8886 in.
2 47.960 - 47.966 mm 1.8884 - 1.8881 in.
3 47.954 - 47.960 mm 1.8879 - 1.8881 in.
Rod Journal- Taper (Max) 0.005 mm 0.0001 in.
Main Bearing Journal Diameter
Journal Grade
0 51.985 - 51.988 mm 2.0466 - 2.0467 in.
1 51.982 - 51.985 mm 2.0465 - 2.0466 in.
2 51.979 - 51.982 mm 2.0464 - 2.0465 in.
3 51.976 - 51.979 mm 2.0462 - 2.0464 in.
4 51.973 - 51.976 mm 2.0461 - 2.0462 in.
Journal Out-of-Round (Max.) 0.005 mm 0.0001 in.
Journal Taper (Max.) 0.006 mm 0.0002 in.
End Play 0.05 - 0.25 mm 0.0019 - 0.0098 in.
Wear Limit 0.30 mm 0.0118 in.
Main Bearing Diametrical Clearance 0.028 - 0.048 mm 0.0011 - 0.0018 in.
Main Bearing Diametrical Clearance (Max) 0.058 mm 0.0022 in.

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

DESCRIPTION

SPECIFICATION

Metric

Standard
Cam Bearing Bore
Front Intake 30.000 - 30.021 mm 1.1810 - 1.1819 in.
Front Exhaust 40.000 - 40.024 mm 1.5747 - 1.5756 in.
Cam Bearing Bore No. 1-4 24.000 - 24.021 mm 0.9448 - 0.9457 in.

CAMSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard
Cam Journal Diameter
Front Intake Cam 29.964 - 29.980 mm 1.1797 - 1.1803 in.
Front Exhaust Cam 35.984 - 36.000 mm 1.4166 - 1.4173 in.
Cam Journal Diameter No. 1-4 23.954 - 23.970 mm 0.943 - 0.944 in.
Bearing Clearance - Diametrical
Front Intake Journal 0.020 - 0.057 mm 0.0008 - 0.0022 in.
Front Exhaust Journal 0.019 - 0.051 mm 0.0007 - 0.0020 in.
All Others 0.020 - 0.067 mm 0.0008 - 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 in.
Intake Valve Timing w/ VVT in lock-pin position*
Closes (ABDC) 49.3°
Opens (ATDC) 10.3°
Duration 219°
Exhaust Valve Timing w/ VVT in lock-pin position*
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.

CYLINDER HEAD

DESCRIPTION

SPECIFICATION

Metric

Standard
Material Cast Aluminum - Heat treated
Gasket Thickness (Compressed) 0.80 mm 0.031 in.
Valve Tappet Bore I.D. 32.000 - 32.025 mm 1.2598 - 1.2608 in.
Valve Tappet O.D. 31.964 - 31.980 mm 1.2584 - 1.2590 in.

VALVE SEAT

DESCRIPTION

SPECIFICATION

Metric

Standard
Angle 44.75° - 45.10°
Seat Outer Diameter - Intake 34.45 - 34.61 mm 1.3562 - 1.3625 in.
Seat Outer 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.
Service Limit 2.0 mm 0.079 in.
Exhaust 1.35 - 1.65 mm 0.0531 - 0.0649 in.
Service Limit 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 Lash
Intake 0.17 - 0.23 mm 0.006 - 0.009 in.
Exhaust 0.27 - 0.33 mm 0.010 - 0.012 in.
Valve Length (Overall)
Intake 113.18 mm 4.455 in.
Exhaust 105.887 mm 4.168 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.