2.4L Engine - Service Information: Specifications

ENGINE SPECIFICATIONS

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Type	In-Line OHV, SOHC
Number of Cylinders	4
Firing Order	1-3-4-2
Compression Ratio	10.5:1
Displacement	2.4 L	146 cu. in.
Bore	86 mm	3.386 in.
Stroke	86 mm	3.386 in.
Compression Pressure	1172 - 1551 kPa	170 - 225 psi
Max. Variation Between Cylinders	25%

GENERAL SPECIFICATIONS

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Material	Cast Aluminum
Cylinder Bore Diameter
A	86.0 - 86.010 mm	3.3858 - 3.3862 in.
B	86.010 - 86.020 mm	3.3862 - 3.3866 in.
C	86.020 - 86.030 mm	3.3866 - 3.3869 in.
Cylinder Bore Out-of-Round (Max.)	0.020 mm	0.0008 in.
Cylinder Bore Taper (Max.)	0.028 mm	0.001 in.
Deck Surface Flatness (Max.)	0.0254 mm	.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.

CYLINDER BLOCK

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Piston Diameter
A	85.995 - 86.015 mm	3.3856 - 3.3864 in.
B	86.005 - 86.025 mm	3.3860 - 3.3868 in.
C	86.015 - 86.035 mm	3.3864 - 3.3872 in.
Clearance to Bore	(-0.015) - 0.015 mm	(-0.0006) - 0.0006 in.
Weight	345 - 355 grams	12.17 - 12.52 oz.
Land Clearance (Diametrical)	0.60 - 0.73 mm	0.0236 - 0.0287 in.
Piston Length	49.0 mm	2.929 in.
Piston Ring Groove Depth No. 1	3.51 - 3.68 mm	0.1382 - 0.0256 in.
Piston Ring Groove Depth No. 2	4.05 - 4.25 mm	0.1594 - 0.1673 in.
Piston Ring Groove Depth No. 3	2.70 - 2.90 mm	0.1063 - 0.1142 in.

PISTONS

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Ring Gap-Top Compression Ring	0.15 - 0.30 mm	0.0059 - 0.0118 in.
Wear Limit	0.8 mm	0.031 in.
Ring Gap-2nd Compression Ring	0.30 - 0.45 mm	0.0118 - 0.0177 in.
Wear Limit	0.8 mm	0.031 in.
Ring Gap-Oil Control Steel Rails	0.20 - 0.70 mm	0.0079 - 0.0276 in.
Wear Limit	1.0 mm	0.039 in.
Ring Side Clearance-Compression Rings	0.03 - 0.07 mm	0.1182 - 0.0028 in.
Wear Limit	0.10 mm	0.004 in.
Ring Side Clearance-Oil Ring Pack	0.06 - 0.15 mm	0.0024 - 0.0059 in.
Ring Width-Top Compression Ring	2.95 - 3.25 mm	0.1161 - 0.1280 in.
Ring Width-2nd Compression Ring	3.45 - 3.75 mm	0.1358 - 0.1476 in.
Ring Width-Oil Ring Pack	2.30 - 2.60 mm	0.0906 - 0.1024 in.
Ring Thickness-Top Compression Ring	1.17 - 1.19 mm	0.0461 - 0.0469 in.
Ring Thickness-2nd Compression Ring	1.17 - 1.19 mm	0.0461 - 0.0469 in.
Ring Thickness-Oil Ring Pack	1.88 - 1.95 mm	0.0740 - 0.0768 in.

PISTON RINGS

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Bearing Clearance	0.032 - 0.060 mm	0.001 - 0.002 in.
Wear Limit	0.070 mm	0.0027 in.
Bore Diameter-Piston Pin	20.974 - 20.985 mm	0.8257 - 0.8261 in.
Bore Diameter-Crankshaft End	51 - 51.015 mm	2.0078 - 2.0084 in.
Side Clearance		0.0039 - 0.0098 in.
Wear Limit
DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Bearing Clearance	0.032 - 0.060 mm	0.001 - 0.002 in.
Wear Limit	0.070 mm	0.0027 in.
Bore Diameter-Piston Pin	20.974 - 20.985 mm	0.8257 - 0.8261 in.
Bore Diameter-Crankshaft End	51 - 51.015 mm	2.0078 - 2.0084 in.
Side Clearance	0.1 - 0.25 mm	0.0039 - 0.0098 in.
Wear Limit	0.27 mm	0.0106 in.
Weight - Total (Less Bearing)	490 grams	17.28 oz.

CONNECTING ROD

DESCRIPTION	SPECIFICATION
DESCRIPTION	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.

CRANKSHAFT

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Cam Bearing Bore
Cam Bearing Bore	24.000 - 24.021 mm	0.9448 - 0.9457 in.

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Cam Journal Diameter
Cam Journal Diameter	23.954 - 23.970 mm	0.943 - 0.944 in.
Bearing Clearance - Diametrical
Cam Journal Clearance	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
Closes (ABDC)	Control By VVAA
Opens (ATDC)	Control By VVAA
Duration	Control By VVAA
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.

CAMSHAFT

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Material	Cast Aluminum - Heat treated
Gasket Thickness (Compressed)	0.54 mm	0.021 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.
Flatness (Head Gasket Surface)	.05 mm	.002 in.

CYLINDER HEAD

DESCRIPTION	SPECIFICATION
DESCRIPTION	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 SEAT

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Diameter I.D.	5.500 - 5.518 mm	0.2165 - 0.2172 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.

VALVE GUIDE

DESCRIPTION	SPECIFICATION
DESCRIPTION	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.

VALVES

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Intake	0.672 mm	0.0264 in.
Exhaust	0.744 mm	0.02929 in.

VALVE MARGIN

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Intake	48.04 mm	1.891 in.
Exhaust	47.99 mm	1.889 in.

VALVE STEM TIP

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
Intake	0.020 - 0.053 mm	0.0008 - 0.0021 in.
Max. Allowable	0.076 mm	0.003 in.
Exhaust	0.030 - 0.060 mm	0.0012 - 0.0024 in.
Max. Allowable	0.101 mm	0.004 in.

VALVE STEM TO GUIDE CLEARANCE

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. @ 1.38 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.

VALVE SPRINGS

DESCRIPTION	SPECIFICATION
DESCRIPTION	Metric	Standard
At Curb Idle Speed*	25 kPa	4 psi. min.
At 3000 RPM	170 - 550 kPa	25 - 80 psi.
CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 RPM.

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

OIL PRESSURE

TORQUE SPECIFICATIONS

DESCRIPTION	N.m	Ft. Lbs.	In. Lbs.
Balance Shaft Module	Refer to tightening sequence Procedure under PUMP, ENGINE OIL - INSTALLATION
Bell Housing-Bolts	50	36
Camshaft Sprocket-Bolt	10 + 65°		89 + 65°
Camshaft Bearing Cap-Bolts	15		133
Coils	8		71
Connecting Rod Cap-Bolts	20 + 90°	15 + 90°
Coolant Temperature Sender	50	36
Crankshaft Main Bearing Cap-Bolts	Refer to tightening sequence Procedure under CRANKSHAFT - INSTALLATION
Crankshaft Damper-Bolt	210	155
Cylinder Head-Bolts	Refer to tightening sequence Procedure under CYLINDER HEAD - INSTALLATION
Cylinder Head Cover-Bolts	10		90
Engine Support Bracket-Bolts	Refer to appropriate Service Information Procedure under ENGINE MOUNTING
Exhaust Manifold-Bolts	34	25
Exhaust Manifold Heat Shield-Bolts	12		105
Flex Plate to Crankshaft-Bolts	95	70
Intake Manifold-Bolts	12	9
Intake Manifold Silencer Cover-Bolts	2.5		22
Ladder Frame-Bolts	Refer to tightening sequence Procedure under FRAME, LADDER - INSTALLATION
Multi Air Fill Port Plug	19	14
Oil Cooler Connector-Bolt	49	36
Oil Filter	14	10
Oil Filter Adapter	49	36
Oil Jet Fastener	12		105
Oil Pan-Bolts
M6 Bolts	12		105
M8 Bolts	22		195
Oil Pan Drain-Plug	40	30
Oil Pressure Switch	48	35
Oil Temperature Sensor	48	35
PCV Valve	4		35
Spark Plugs	27	20
Thermostat Housing-Bolts	9		80
Timing Chain Cover-Bolts
M10 Bolts	65	48
M6 Bolts	9		80
M8 Bolts	26	19
Timing Chain Tensioner Assembly-Bolts	12		105
Timing Chain Guide-Bolts (stationary guide)	12		106
Timing Chain Guide-Bolts (pivoting guide)	28	21
Timing Chain Tensioner-Bolts	9		80
Vacuum Pump-Bolts	20	15

OIL FILTER SPECIFICATION

All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar® or the equivalent.

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ENGINE SPECIFICATIONS

TORQUE SPECIFICATIONS

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