Material Specifications
| Item | Specification | Fill Capacity |
|---|---|---|
| Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada) | WSS-M2C945-A | 5.4L (5.7 qt) includes filter change |
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) | 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) |
| 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) | 18 kg (39.683 lb) |
| Intake (valve open) 9.2 mm (0.362 in) of lift | 46 kg (101.41 lb) |
| Exhaust (valve open) 9.2 mm (0.362 in) of lift | 46 kg (101.41 lb) |
| Free length | 47.91 mm (1.886 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 (0.008-0.018 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 | 9.44 mm (0.371 in) |
| Lobe lift - exhaust | 8.18 mm (0.322 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 bolt | 11 | 97 | |
| Accessory drive belt tensioner bolts | 25 | 18 | |
| Balance unit bolts (1) | |||
| Blocker heater | 40 | 30 | |
| Camshaft bearing cap bolts (1) | |||
| Camshaft Position (CMP) sensor bolt | 7 | 62 | |
| Camshaft sprocket bolts (1) | |||
| 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 block pipe plug | 56 | 41 | |
| Cylinder head assembly plug bolt | 11 | 97 | |
| Cylinder head bolts (1) | |||
| Cylinder Head Temperature (CHT) sensor | 12 | 106 | |
| 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 | 90 | 66 | |
| Engine mount nuts | 80 | 59 | |
| Engine mount studs | 12 | 106 | |
| Engine Oil Pressure (EOP) switch | 15 | 133 | |
| Engine lift eye bolts | 47 | 35 | |
| Engine plug bolt | 20 | 177 | |
| Engine-to-bellhousing bolts | 48 | 35 | |
| Exhaust hanger bolts | 25 | 18 | |
| Exhaust manifold bracket-to-cylinder block bolts | 48 | 35 | |
| Exhaust manifold bracket-to-exhaust bolts | 25 | 18 | |
| Exhaust manifold heat shield bolts | 11 | 97 | |
| Exhaust manifold nuts | 55 | 41 | |
| Exhaust manifold studs | 17 | 150 | |
| Exhaust pipe flange nuts | 48 | 35 | |
| Flexplate bolts (1) | |||
| Front brace bolts | 20 | 177 | |
| Fuel rail stud bolts | 23 | 17 | |
| Generator electrical connection nut | 15 | 133 | |
| Generator mounting bolts | 25 | 18 | |
| Generator mounting bracket nut and bolt | 25 | 18 | |
| Generator mounting bracket stud | 7 | 62 | |
| Ground cable bolts | 23 | 17 | |
| Half shaft bracket bolts | 48 | 35 | |
| Intake manifold bolts (1) | |||
| Knock Sensor (KS) bolt | 20 | 177 | |
| LH transaxle mount bolt | 148 | 109 | |
| Main bearing beam bolts (1) | |||
| Oil filter adapter bolts | 25 | 18 | |
| 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 squirters | 4 | 35 | |
| Power Distribution Box (PDB) cable nut | 12 | 106 | |
| Radio capacitor nut | 10 | 89 | |
| Roll restrictor bolts | 125 | 92 | |
| Shift cable bracket bolts | 25 | 18 | |
| Spark plug | 12 | 106 | |
| Starter motor bolts | 35 | 26 | |
| Starter motor bracket nuts | 18 | 159 | |
| Starter motor solenoid nut | 12 | 106 | |
| Starter motor ground wire nut | 5 | 44 | |
| Thermostat housing bolts | 10 | 89 | |
| Timing chain guide bolts | 10 | 89 | |
| Timing chain tensioner bolts | 10 | 89 | |
| Torque converter nuts | 40 | 30 | |
| Transaxle-to-engine bolts | 48 | 35 | |
| Transmission cooler tube bolts | 9 | 80 | |
| Valve cover bolts (1) | |||
| Valve cover bracket nuts | 9 | 80 | |
| Variable Camshaft Timing (VCT) oil control solenoid bolt | 11 | 97 | |
| VCT cylinder head plug bolt | 11 | 97 | |
| (1) Refer to the procedure for this 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 the procedure for this 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)
- Composite intake manifold
- Aluminum cylinder head
- Aluminum cylinder block
- Electronic ignition system with coil-on-plug 4 ignition coils
Note. For additional information, refer to the exploded views under the ENGINE - Assembly procedure.
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. The engine is at a 10 degree tilt toward the bulkhead in the vehicle.