MATERIAL SPECIFICATIONS
| Item | Specification | Fill Capacity |
|---|---|---|
| Motorcraft® Metal Surface Prep ZC-31-A | ||
| Motorcraft® Premium Gold Engine Coolant with Bittering Agent (bittered in US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) | WSS-M97B51-A1 | |
| Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent | WSS-M2C930-A | 4.25L (4.5 qt) includes filter change |
| Multi-Purpose Grease XG-4 and/or XL-5 | ESB-M1C93-B | |
| Silicone Brake Caliper Grease and Dielectric Compound XG-3-A | ESE-M1C171-A | |
| Silicone Gasket and Sealant TA-30 | WSE-M4G323-A4 | |
| Silicone Gasket Remover ZC-30 | ||
| Thread Sealant with PTFE TA-24 | WSK-M2G350-A2 |
MATERIAL SPECIFICATIONS
GENERAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Displacement | 2.5L |
| No. of cylinders | 4 |
| Bore/stroke | 89/100 |
| Firing order | 1-3-4-2 |
| Oil pressure (hot @ 2,000 RPM) | 29-39 psi 200-268 kPa |
| Compression ratio | 12.5:1 |
| Engine weight (without accessory drive components) | 121.3 kg (267.5 lb) |
| Engine and transaxle weight (without accessory drive components) | 251.3 kg (554 lb) |
| Cylinder Block | |
| Cylinder bore diameter | 89-89.3 mm (3.503-3.517 in) |
| Cylinder bore maximum out-of-round | 0.008 mm (0.0003 in) |
| Main bearing bore diameter | 57.018-57.040 mm (2.244-2.245 in) |
| Head gasket surface flatness | 0.1 mm/general 0.05 mm/200 x 200 (0.003 in/general) (0.0019 in/7.87 x 7.87) |
| Piston | |
| Diameter (1) | 88.965-88.975 mm (3.5025-3.5026 in) |
| Diameter (2) | 88.975-88.985 mm (3.5026-3.5033 in) |
| Diameter (3) | 88.985-88.995 mm (3.5033-3.5037 in) |
| Piston-to-bore clearance | 0.025-0.045 mm (0.0009-0.0017 in) |
| Ring groove width - top | 1.203-1.205 mm (0.0473-0.0474 in) |
| Ring groove width - 2nd | 1.202-1.204 mm (0.0473-0.0474 in) |
| Ring groove width - oil | 2.501-2.503 mm (0.0984-0.0985 in) |
| Piston skirt coating thickness | 0.008-0.016 mm (0.0003-0.0006 in) |
| Piston Pin | |
| Diameter | 19.995-20 mm (0.7872-0.7874 in) |
| Length | 54.7-55 mm (2.153-2.165 in) |
| Piston-to-pin clearance | Floating Pin |
| Pin-to-rod clearance | Clips |
| Cylinder Head | |
| Cylinder head flatness | 0.08 mm (0.0031 in) maximum overall, a maximum of 0.05 mm (0.0019 in) within 150 mm (5.9 in) |
| Valve lift @ zero lash (exhaust) | 7.7 mm (0.30 in) |
| Valve lift @ zero lash (intake) | 8.8 mm (0.35 in) |
| Valve guide diameter | 5.509-5.539 mm (0.216-0.218 in) |
| Valve seat width - intake/exhaust | 0.99-1.84 mm (0.038-0.072 in) |
| Valve seat angle | 45 degrees |
| Valve seat runout | 0.075 mm (0.0029 in) |
| Valve lash adjuster bore diameter | 31.00-31.03 mm (1.220-1.221 in) |
| Cam bore diameter | 25.015-25.040 mm (0.984-0.985 in) |
| Valve | |
| Valve head diameter - intake | 34.85-35.15 mm (1.372-1.383 in) |
| Valve head diameter - exhaust | 29.85-30.15 mm (1.175-1.187 in) |
| Valve stem diameter - intake | 5.470-5.485 mm (0.2153-0.2159 in) |
| Valve stem diameter - exhaust | 5.465-5.480 mm (0.2151-0.2157 in) |
| Valve stem-to-guide clearance - intake | 0.0027 mm (0.00010 in) |
| Valve stem-to-guide clearance - exhaust | 0.0029 mm (0.00011 in) |
| Valve face runout (maximum) | 0.075 mm (0.0029 in) |
| Valve face angle | 45 degrees |
| Valve Spring - Compression Pressure | |
| Intake and exhaust (installed) | 38.667 lb |
| Intake (valve open) 8.9 mm (0.35 in) of lift | 97.032 lb |
| Exhaust (valve open) 7.4 mm of lift | 93.338 lb |
| Free length | 44.92 mm (1.768 in) |
| Assembled height | 37.9 mm (1.492 in) |
| Crankshaft | |
| Main bearing journal diameter | 51.978-52.002 mm (2.046-2.047 in) |
| Production repair | 51.730-51.750 mm (2.036-2.037 in) |
| Main bearing clearance | 0.016-0.047 mm (0.0006-0.0015 in) |
| Connecting rod journal diameter | 51.978-52.002 mm (2.0463-2.0473 in) |
| Production repair | 51.730-51.750 mm (2.0366-2.0374 in) |
| End play | 0.22-0.43 mm (0.008-0.016 in) |
| Rings | |
| Width - top | 1.17-1.185 mm (0.0460-0.0466 in) |
| Width - 2nd | 1.197-1.199 mm (0.0471-0.0472 in) |
| Width - oil | 2.38-2.45 mm (0.093-0.096 in) |
| Ring gap (in bore) - top | 0.16-0.26 mm (0.006-0.010 in) |
| Ring gap (in bore) - 2nd | 0.31-0.46 mm (0.012-0.018 in) |
| Ring gap (in bore) - oil | 0.2-0.7 mm (0.007-0.027 in) |
| Valve Tappet | |
| Diameter | 30.97-30.98 mm (1.2192-1.2196 in) |
| Tappet-to-valve clearance - intake | 0.22-0.28 mm (0.008-0.011 in) |
| Tappet-to-valve clearance - exhaust | 0.27-0.33 mm (0.010-0.013 in) |
| Tappet-to-bore clearance | 0.02-0.06 mm (0.0007-0.0023 in) |
| Camshaft | |
| Lobe lift - intake | 8.24999 mm (0.324 in) |
| Lobe lift - exhaust | 7.80007 mm (0.307 in) |
| Runout (l) (1) | 0.03 mm (0.001 in) |
| Thrust clearance | 0.09-0.24 mm (0.003-0.009 in) |
| Journal diameter | 24.96-24.98 mm (0.982-0.983 in) |
| Journal-to-bore clearance | 0.035-0.080 mm (0.001-0.003 in) |
| Connecting Rod | |
| Bearing clearance | 0.027-0.052 mm (0.001-0.002 in) |
| Bearing thickness | 1.496-1.520 mm (0.058-0.059 in) |
| Crank bore diameter | 55.023-55.047 mm (2.166-2.167 in) |
| Pin bore diameter | 20.965-20.985 mm (0.825-0.826 in) |
| Length (center to center) | 151.8 mm (5.976 in) |
| Side clearance | 1.95-3.05 mm (0.076-0.120 in) |
| Axial clearance | 0.14-0.36 mm (0.005-0.014 in) |
| (1) No. 3 Journal - Supported by No. 1 and No. 5 journals. | |
| (1) | No. 3 Journal - Supported by No. 1 and No. 5 journals. |
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
| Description | Nm | Lb-ft | Lb-in |
|---|---|---|---|
| ABS sensor bolt | 15 | 133 | |
| A/C compressor mounting bolts | 25 | 18 | |
| A/C manifold tube bolt | 20 | 177 | |
| A/C tube bracket nut | 10 | 89 | |
| Accessory drive belt tensioner | 25 | 18 | |
| Air Cleaner (ACL) outlet tube clamps | 3 | 27 | |
| Auxiliary coolant pump bolts | 10 | 89 | |
| Balance shaft bolts (1) | |||
| Belt tensioner bolt | 25 | 18 | |
| Block heater (if equipped) | 40 | 30 | |
| Block-off plate bolts | 25 | 18 | |
| Camshaft bearing caps (1) | |||
| Camshaft Position (CMP) sensor bolt | 7 | 62 | |
| Camshaft sprocket bolt | 72 | 53 | |
| Catalytic converter-to-cylinder head nuts (1) | |||
| Coil-on-plug retaining stud bolts | 8 | 71 | |
| Connecting rod cap bolts (1) | |||
| Coolant outlet bolts | 10 | 89 | |
| Coolant pump bolts | 10 | 89 | |
| Coolant pump pulley bolts | 20 | 177 | |
| Crankcase vent oil separator bolts | 10 | 89 | |
| Crankshaft Position (CKP) sensor | 7 | 62 | |
| Crankshaft pulley bolt (1) | |||
| Cylinder head bolts (1) | |||
| Cylinder Head Temperature (CHT) sensor | 12 | 106 | |
| DC-to-DC converter nuts | 12 | 106 | |
| EGR tube | 55 | 41 | |
| EGR valve assembly bolts | 20 | 177 | |
| Engine front cover bolts (1) | |||
| Engine Oil Pressure (EOP) switch | 15 | 133 | |
| Engine mount bolts | 48 | 35 | |
| Engine mount bracket-to-engine nuts | 115 | 85 | |
| Engine mount bracket-to-mount bolt | 115 | 85 | |
| Engine plug bolt | 20 | 177 | |
| Engine roll-restrictor bolts (rear) | 90 | 66 | |
| Engine support crossmember bolts | 90 | 66 | |
| Engine support crossmember nut | 175 | 129 | |
| Engine timing plug bolt | 20 | 177 | |
| Engine-to-transmission bolts | 48 | 35 | |
| Engine wiring harness connector bracket | 15 | 133 | |
| Exhaust bracket bolts | 25 | 18 | |
| Exhaust manifold studs | 17 | 150 | |
| Flywheel bolt (1) | |||
| Fuel rail bolts | 23 | 17 | |
| Intake manifold bolts | 18 | 159 | |
| Intermediate shaft bearing retainer nuts | 27 | 20 | |
| Knock Sensor (KS) | 20 | 177 | |
| Lateral support crossmember bolts | 115 | 85 | |
| Lower insulator through bolt | 115 | 85 | |
| Lower front cover timing hole plug | 12 | 106 | |
| Main bearing beam bolts (1) | |||
| Motor Electronics Cooling System (MECS) pump bolts | 20 | 177 | |
| Oil drain plug | 28 | 21 | |
| Oil filter adapter bolts | 25 | 18 | |
| Oil filter cover (replaceable element filter type) | 33 | 24 | |
| Oil filter drain plug | 10 | 89 | |
| Oil filter (spin-on filter type) (2) | |||
| Oil pan bolts (1) | |||
| Oil pan-to-bellhousing bolts | 48 | 35 | |
| Oil pump drive chain tensioner shoulder bolts | 10 | 89 | |
| Oil pump screen and cover assembly | 10 | 89 | |
| Oil pump sprocket bolt | 25 | 18 | |
| Oil pump-to-engine block bolts (1) | |||
| Oil squirters | 4 | 35 | |
| Power Transfer Unit (PTU) bolts | 45 | 33 | |
| PTU heat shield bolts | 11 | 97 | |
| PTU-to-engine support bracket bolts | 40 | 30 | |
| Radio capacitor nut | 10 | 89 | |
| Rear crankshaft oil seal retainer (1) | |||
| Rear insulator through bolt | 115 | 85 | |
| Rear main seal mounting plate bolts | 10 | 89 | |
| Rear roll restrictor bracket bolts | 55 | 41 | |
| Rear roll restrictor-to-crossmember through bolt | 90 | 66 | |
| Spark plug | 12 | 106 | |
| Splash shield bolts | 9 | 80 | |
| Stabilizer bar link nuts | 63 | 46 | |
| Steering column coupling-to-steering gear pinch bolt | 40 | 30 | |
| Subframe bolts | 175 | 129 | |
| Subframe nuts | 150 | 111 | |
| Thermostat housing bolts | 10 | 89 | |
| Tie-rod end nuts | 55 | 41 | |
| Timing chain guide bolts | 10 | 89 | |
| Timing chain tensioner bolts | 10 | 89 | |
| Transaxle control cable bracket nuts | 22 | 16 | |
| Transaxle control snow shield bolts | 22 | 16 | |
| Transaxle damper bolts | 29 | 21 | |
| Transaxle harness electrical connector bolt | 10 | 89 | |
| Transaxle mount bolts | 90 | 66 | |
| Transaxle mount nuts | 90 | 66 | |
| Transaxle-to-engine bolts | 48 | 35 | |
| Upper transaxle insulator bracket | 25 | 18 | |
| Upper transaxle insulator nuts | 90 | 66 | |
| Upper transaxle insulator through bolt | 103 | 76 | |
| Upper front cover timing hole plug | 10 | 89 | |
| Vacuum pump assembly bolts | 25 | 18 | |
| Vacuum pump assembly nut | 25 | 18 | |
| Valve cover bolts (1) | |||
| Variable Camshaft Timing (VCT) plug | 17 | 150 | |
| VCT solenoid bolt | 10 | 89 | |
| Wiring harness ground cable nut | 20 | 177 | |
| (1) See procedure for specification. (2) Lubricate the spin-on oil filter gasket with clean engine oil. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter. | |||
| (1) | See procedure for specification. |
| (2) | Lubricate the spin-on oil filter gasket with clean engine oil. Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter. |
TORQUE SPECIFICATIONS
The 2.5L (153 CID) 4-cylinder engine has the following features
- Dual overhead camshaft
- Four valves per cylinder
- Sequential Multi-Port Fuel Injection (SFI)
- Aluminum cylinder head
- Aluminum cylinder block
- Electronic ignition system with 4 coil-on-plug ignition coils
The 2.5L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a coil-on-plug ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the ladder assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transmission to provide greater strength. The camshafts are mounted in the cylinder heads and act against valve tappets to open and close the valves. The camshafts are driven off the front of the cylinder head by one timing chain. The chain is driven by a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston with a cast iron connecting rod. The oil pump is driven by the crankshaft via a dedicated chain that is driven by the same sprocket that drives the timing chain.
See also:
• JACKING & LIFTING
• SUPPLEMENTAL RESTRAINT SYSTEM