MATERIAL SPECIFICATIONS
| Item | Specification | Fill Capacity |
|---|---|---|
| High Temperature 4x4 Front Axle and Wheel Bearing Grease XG-11 | WSS-M1C267-A1 | |
| 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 | 89.0/100.0 |
| Firing order | 1-3-4-2 |
| Oil pressure (hot @ 2,000 rpm) | 200-268 kPa (29-39 psi) |
| Compression ratio | 9.7:1 |
| Engine weight (without accessory drive components and flexplate or flywheel) | 115.8 kg (255.3 lb) |
| Engine and transaxle assembly weight (without accessory drive components) | 203.8 kg (449.3 lb) |
| Cylinder Block | |
| Cylinder bore diameter | 89.0-89.03 mm (3.503-3.505 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 (0.004 in/general) (0.0019 in/7.87 x 7.87) |
| Piston | |
| Diameter (1) | 88.965-88.975 mm (3.5025-3.5029 in) |
| Diameter (2) | 88.975-88.985 mm (3.5029-3.5033 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 | 19.995-20.0 mm (0.8265-0.8267 in) |
| Length | 54.7-55.0 mm (2.1535-2.1653 in) |
| Piston-to-pin clearance | Floating pin |
| Pin-to-rod clearance | Clip |
| Cylinder Head | |
| Cylinder head flatness | 0.08 (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 | 0.05 mm (0.0019 in) |
| Valve face angle | 45 degrees |
| Valve Spring - Compression Pressure | |
| Intake and exhaust (installed) | 17.5 kg (38.667 lb) |
| Intake (valve open) 8.9 mm (0.35 in) of lift | 44 kg (97.032 lb) |
| Exhaust (valve open) | 7.4 mm of lift 42 kg (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 (2.046-2.047 in) |
| Production repair | 51.730-51.750 mm (2.036-2.037 in) |
| End play | 0.220-0.450 mm (0.007-0.018 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 | 0.16-0.31 mm (0.006-0.012 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 (1) (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 |
|---|---|---|---|
| A/C compressor mounting bolts | 25 | 18 | |
| Accessory drive belt idler pulley and bracket bolts | 25 | 18 | |
| Accessory drive belt idler pulley bolt | 25 | 18 | |
| Accessory drive belt tensioner bolts | 25 | 18 | |
| Air Cleaner (ACL) outlet pipe-to-Throttle Body (TB) clamp | 4 | 35 | |
| Balance shaft bolts (1) | |||
| Bellhousing-to-engine bolts | 48 | 35 | |
| Blocker heater | 40 | 30 | |
| Camshaft bearing cap bolts (1) | |||
| Camshaft sprocket bolts | 72 | 53 | |
| Clutch hydraulic line | 25 | 18 | |
| Clutch hydraulic line bracket-to-transaxle bolt | 3 | 27 | |
| Coil-on-plug 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 bolts (1) | |||
| Crankshaft pulley bolt (1) | |||
| Crankshaft rear oil seal retainer bolts (1) | |||
| Cylinder head bolts (1) | |||
| Cylinder Head Temperature (CHT) sensor | 12 | 106 | |
| Dampener bolts | 40 | 30 | |
| Driveshaft bolts | 37 | 27 | |
| EGR tube | 55 | 41 | |
| EGR valve bolts | 20 | 177 | |
| Engine front cover bolts (1) | |||
| Engine front cover-to-oil pan bolts (1) | |||
| Engine mount bolts | 55 | 41 | |
| Engine mount bracket bolt | 115 | 85 | |
| Engine mount bracket nuts | 115 | 85 | |
| Engine Oil Pressure (EOP) switch | 15 | 133 | |
| Engine plug bolt | 20 | 177 | |
| Engine support crossmember bolts | 90 | 66 | |
| Engine support crossmember nut | 175 | 129 | |
| Engine-to-bellhousing bolts | 48 | 35 | |
| Exhaust manifold heat shield bolts | 10 | 89 | |
| Exhaust manifold nuts (1) | |||
| Exhaust manifold stud bolts | 17 | 150 | |
| Flexplate bolts (1) | |||
| Flywheel bolts (1) | |||
| Fuel rail stud bolts | 23 | 17 | |
| Generator electrical connection nut | 6 | 53 | |
| Generator mounting bolt and nuts | 47 | 35 | |
| Ground eyelet bolt | 10 | 89 | |
| Ground strap bolt | 10 | 89 | |
| Intake manifold bolts | 18 | 159 | |
| Intermediate shaft bearing retainer nuts | 27 | 20 | |
| Knock Sensor (KS) bolt | 20 | 177 | |
| Lateral support crossmember bolts | 115 | 85 | |
| LH splash shield bolts | 9 | 80 | |
| LH transaxle mount bolt | 103 | 76 | |
| Lower front cover timing hole plug | 12 | 106 | |
| Main bearing beam bolts (1) | |||
| 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-to-bellhousing bolts (1) | |||
| Oil pan bolts (1) | |||
| Oil pan drain plug | 28 | 21 | |
| Oil pump drive chain tensioner bolt | 10 | 89 | |
| Oil pump drive chain tensioner shoulder bolt | 10 | 89 | |
| Oil pump bolts (1) | |||
| Oil pump screen and pickup tube bolts | 10 | 89 | |
| Oil pump sprocket bolt | 25 | 18 | |
| Oil squirts | 4 | 35 | |
| Power Distribution Box (PDB) cable nut | 12 | 106 | |
| Power Transfer Unit (PTU) bolts | 70 | 52 | |
| PTU bracket bolts | 45 | 33 | |
| PTU bracket-to-engine bolts | 40 | 30 | |
| PTU heat shield bolts | 11 | 97 | |
| PTU lower LH bolt | 45 | 33 | |
| Pressure plate bolts | 29 | 21 | |
| Radio capacitor bolt | 20 | 177 | |
| Radio capacitor nut | 10 | 89 | |
| Rear transaxle mount bolt | 115 | 85 | |
| RH splash shield bolts | 9 | 80 | |
| Shift cable bracket bolts | 22 | 16 | |
| Spark plug | 12 | 106 | |
| Starter motor bolts | 35 | 26 | |
| Starter motor solenoid battery nut | 12 | 106 | |
| Starter motor solenoid nut | 5 | 44 | |
| Starter motor ground wire nut | 25 | 18 | |
| Thermostat housing bolts | 10 | 89 | |
| Timing chain guide bolts | 10 | 89 | |
| Timing chain tensioner bolts | 10 | 89 | |
| Torque converter nuts | 35 | 26 | |
| Transaxle-to-engine bolts | 48 | 35 | |
| Transaxle-to-PTU bolt | 48 | 35 | |
| Upper engine bracket-to-PTU bolts | 45 | 33 | |
| Upper front cover timing hole plug | 10 | 89 | |
| Valve cover bolts (1) | |||
| Variable Camshaft Timing (VCT) oil control solenoid bolt | 10 | 89 | |
| VCT system oil filter plug | 17 | 150 | |
| (1) Refer to 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) | Refer to 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 coil-on-plug 4 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.