GENERAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Engine | |
| Displacement | 2.0L |
| No. of cylinders | 4 |
| Bore/stroke | 87.5/83.1 |
| Firing order | 1-3-4-2 |
| Oil pressure (hot @ 2,000 RPM) | 200-268 kPa (29-39 psi) |
| Belt tension | Refer to ACCESSORY DRIVE article. |
| Oil capacity | 3.9L + 0.38L (4.1 qt + 0.4 qt) with filter |
| Cylinder Block | |
| Cylinder bore diameter | 87.5-87.53 mm (3.444-3.445 in) |
| Cylinder bore maximum out-of-round | 0.008 mm (0.0003 in) |
| Main bearing bore diameter | 57.020-57.038 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) | 87.5-87.51 mm (3.444-3.445 in) |
| Diameter (2) | 87.51-87.52 mm (3.4452-3.4456 in) |
| Diameter (3) | 87.52-87.53 mm (3.444-3.446 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 | 1.17-1.19 mm (0.0.460-0.0468 in) |
| Ring groove width - oil | 2.501-2.503 mm (0.0984-0.0985 in) |
| Piston skirt coating thickness | 0.008-0.020 mm (0.0003-0.0007 in) |
| Piston Pin | |
| Diameter | 20.995-21.0 mm (0.8266-0.8268 in) |
| Length | 59.6-60.4 mm (2.346-2.377 in) |
| Piston-to-pin clearance | 0.008-0.016 mm (0.0003-0.0006 in) |
| Pin-to-rod clearance | Press fit |
| Cylinder Head | |
| 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 (0.0001 in) |
| Valve stem-to-guide clearance - exhaust | 0.0029 mm (0.00011 in) |
| Valve face runout | 0.05 mm (0.001 in) |
| Valve face angle | 45 degrees |
| Valve Spring - Compression Pressure | |
| Intake and exhaust (installed) | 17.5 kg (38.667 lbs) |
| Intake (valve open) 8.9 mm (0.35 in) of lift | 44 kg (97.032 lbs) |
| Exhaust (valve open) 7.4 mm (0.29 in) of lift | 42 kg (93.338 lbs) |
| Free length | 44.92 mm (1.768 in) |
| Assembled height | 37.9 mm (1.492 in) |
| Crankshaft | |
| Main bearing journal diameter | 51.980-52.000 mm (2.046-2.047 in) |
| Production repair | 51.730-51.750 mm (2.036-2.037 in) |
| Main bearing clearance | 0.019-0.035 mm (0.0007-0.0013 in) |
| Connecting rod journal diameter | 49.980-50.000 mm (1.967-1.968 in) |
| Production repair | 49.730-49.750 mm (1.957-1.958 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 | 0.16-0.31 mm (0.006-0.012 in) |
| Ring gap (in bore) - 2nd | 0.33-0.48 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) a | 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 | 53.025-53.045 mm (2.087-2.088 in) |
| Pin bore diameter | 20.965-20.985 mm (0.825-0.826 in) |
| Length (center to center) | 154.8 mm (6.094 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) |
GENERAL SPECIFICATIONS
a No. 3 Journal - Supported by No. 1 and No. 5 journals.
| Item | Specification |
|---|---|
| Engine | |
| Displacement | 2.3L |
| No. of cylinders | 4 |
| Bore/stroke | 87.5/94.0 |
| Firing order | 1-3-4-2 |
| Oil pressure (hot @ 2,000 RPM) | 200-268 kPa (29-39 psi) |
| Belt tension | Refer to ACCESSORY DRIVE article. |
| Oil capacity | 3.9L + 0.38L (4.1 qt + 0.4 qt) with filter |
| Cylinder Block | |
| Cylinder bore diameter | 87.5-87.53 mm (3.444-3.446 in) |
| Cylinder bore maximum out-of-round | 0.008 mm (0.0003 in) |
| Main bearing bore diameter | 57.020-57.038 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) | 87.5-87.51 mm (3.444-3.445 in) |
| Diameter (2) | 87.51-87.52 mm (3.4452-3.4456 in) |
| Diameter (3) | 87.52-87.53 mm (3.4456-3.4460 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 | 1.17-1.19 mm (0.0460-0.0468 in) |
| Ring groove width - oil | 2.501-2.503 mm (0.0984-0.0985 in) |
| Piston skirt coating thickness | 0.008-0.020 mm (0.0003-0.0007 in) |
| Piston Pin | |
| Diameter | 20.995-21.0 mm (0.8265-0.8267 in) |
| Length | 59.6-60.4 mm (2.346-2.377 in) |
| Piston-to-pin clearance | 0.008-0.016 mm (0.0003-0.0006 in) |
| Pin-to-rod clearance | Press fit |
| Cylinder Head | |
| Valve lift @ zero lash (exhaust) | 7.4 mm (0.30 in) |
| Valve lift @ zero lash (intake) | 7.9 mm (0.31 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 (0.29 in) 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 | 51.980-52.000 mm (2.046-2.047 in) |
| Production repair | 51.730-51.750 mm (2.036-2.037 in) |
| Main bearing clearance | 0.019-0.035 mm (0.0007-0.0013 in) |
| Connecting rod journal diameter | 49.980-50.000 mm (1.967-1.968 in) |
| Production repair | 49.730-49.750 mm (1.957-1.958 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 | 0.16-0.31 mm (0.006-0.012 in) |
| Ring gap (in bore) - 2nd | 0.33-0.48 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) a | 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 | 53.025-53.045 mm (2.087-2.088 in) |
| Pin bore diameter | 20.965-20.985 mm (0.825-0.826 in) |
| Length (center to center) | 154.8 mm (6.094 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) |
GENERAL SPECIFICATIONS
a No. 3 Journal - Supported by No. 1 and No. 5 journals.
| Item | Specification |
|---|---|
| Motorcraft Metal Surface Cleaner ZC-21 | WSE-M5B392-A |
| Silicone Gasket Remover ZC-30 | |
| Motorcraft Metal Surface Prep ZC-31 | |
| Silicone Gasket and Sealant TA-30 | WSE-M4G323-A4 |
| 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 |
| Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) | WSS-M97B51-A1 |
| Multi-Purpose Grease XG-4 and/or XL-5 | ESB-M1C93-B |
| Thread Sealant with PTFE TA-24 | WSK-M2G350-A2 |
| High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A | ESA-M1C198-A |
| Silicone Brake Caliper Grease and Dielectic Compound XG-3-A | ESE-M1C17-A |
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
| Description | Nm |
|---|---|
| A/C compressor mounting bolts | 25 |
| A/C manifold tube bolt | 21 |
| Accelerator cable bracket | 10 |
| Accelerator control snow shield | 10 |
| Accessory drive belt idler bolt | 25 |
| Accessory drive belt tensioner bolt | 25 |
| Air cleaner outlet tube clamps | 4 |
| Bellhousing-to-engine bolts | 48 |
| Bellhousing-to-engine stud bolt | 48 |
| Block heater (if equipped) | 21 |
| Camshaft bearing caps a | |
| Camshaft sprocket bolt | 72 |
| Catalytic converter heat shield bolts | 11 |
| Catalytic converter nuts | 55 |
| Catalytic converter support bracket | 47 |
| Catalytic converter support bracket bolts | 47 |
| Catalytic converter-to-cylinder head nuts a | |
| Catalytic converter-to-exhaust system nuts | 47 |
| Catalytic converter-to-muffler assembly nuts | 47 |
| Coil-on-plug retaining bolt | 10 |
| Coolant expansion tank bolt | 10 |
| Coolant outlet bolts | 10 |
| Coolant pump bolts | 10 |
| Coolant pump pulley bolts | 20 |
| Crankcase ventilation cover assembly bolts | 10 |
| Crankshaft oil seal retainer bolts a | |
| Crankshaft position (CKP) sensor a | |
| Crankshaft pulley bolt a | |
| Cylinder head bolts a | |
| Cylinder head temperature (CHT) sensor | 12 |
| EGR tube nut | 55 |
| Engine front cover bolts a | |
| Engine front cover-to-oil pan bolts a | |
| Engine ground cable bolt | 48 |
| Engine lifting eye bolts | 45 |
| Engine plug bolt | 20 |
| Engine-to-bellhousing bolts | 48 |
| Engine-to-bellhousing stud bolt | 48 |
| Exhaust gas recirculation (EGR) valve assembly bolts | 20 |
| Flexplate bolts a | |
| Flywheel bolts a | |
| Front brake caliper | 28 |
| Fuel rail bolt | 25 |
| Generator B+ cable | 8 |
| Generator B+ cable retainer | 25 |
| Generator heat shield | 18 |
| Generator mounting bolts | 25 |
| Heated oxygen sensor (HO2S) and catalyst monitor sensor wire connector bracket nuts | 25 |
| Intake manifold bolts | 18 |
| Intermediate shaft bracket-to-engine bolt | 40 |
| Intermediate shaft mounting bracket bolt | 25 |
| Knock sensor (KS) | 20 |
| Motor mount bracket bolts | 48 |
| Motor mount nuts | 90 |
| Oil drain plug | 28 |
| Oil filter adapter bolts | 25 |
| Oil level indicator tube bolt(s) | 10 |
| Oil pan bolts a | |
| Oil pan-to-bellhousing bolts a | |
| Oil pressure sensor | 15 |
| Oil pump drive chain guide bolts (early build) | 10 |
| Oil pump drive chain tensioner shoulder bolts | 10 |
| Oil pump screen and cover assembly | 10 |
| Oil pump sprocket bolt | 25 |
| Oil pump-to-engine block bolts a | |
| PSP tube bracket nut | 11 |
| Power distribution harness eyelet nut | 10 |
| Power steering pressure (PSP) tube nut | 65 |
| Power steering pump mounting bolts | 25 |
| Pressure plate bolts | 27 |
| Radio interference capacitor bracket | 10 |
| Radio interference capacitor ground | 10 |
| Rear transaxle mounting nut | 133 |
| Spark plugs | 12 |
| Stabilizer bar | 55 |
| Starter B+ cable | 12 |
| Starter motor mounting bolts | 25 |
| Starter relay | 5 |
| Suspension arm ball joint bolt | 63 |
| Thermostat housing assembly bolts | 10 |
| Tie-rod end nut | 40 |
| Timing chain guide bolts | 10 |
| Timing chain tensioner bolts | 10 |
| Torque converter-to-flexplate nuts | 35 |
| Transaxle roll-restrictor bolts | 48 |
| Upper strut mount nuts | 30 |
| Valve cover bolts a | |
| Valve cover retainers | 10 |
TORQUE SPECIFICATIONS
a See procedure for specification.
The 2.0L and 2.3L engines are 4 valve-per-cylinder, dual overhead camshaft engines. The engines use a coil-on-plug ignition system. The cylinder blocks are made of aluminum and the bearing caps are integrated into the ladder assemblies. 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 powdered metal 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.
Refer to ENGINE SYSTEM - GENERAL INFORMATION article for basic mechanical concerns or refer to the INTRODUCTION - GASOLINE ENGINES article for driveability concerns.
See also:
• JACKING AND LIFTING