MATERIAL SPECIFICATION
| Item | Specification | Fill Capacity |
|---|---|---|
| High Temperature 4x4 Front Axle and Wheel Bearing Grease XG-11 | WSSM1C267-A1 | |
| Motorcraft® Metal Surface Prep ZC-31-A | ||
| Motorcraft® Premium Gold Engine Coolant with Bittering Agent (US); Motorcraft® Premium Gold Engine Coolant (Canada) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) | WSSM97B51-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 | WSSM2C930-A | 3.8L (4 qt) with 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 | WSEM4G323-A4 | |
| Silicone Gasket Remover ZC-30 | ||
| Thread Sealant with PTFE TA-24 | WSKM2G350-A2 |
MATERIAL SPECIFICATION
GENERAL SPECIFICATION
| Item | Specification |
|---|---|
| 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) |
| Engine weight (without accessory drive components) | 133 kg (293 lb) |
| Cylinder Block | |
| Cylinder bore diameter | 87.5-87.53 mm (3.444-3.445 in) |
| Out of round | 0.008 mm (0.0003 in) |
| Main bearing bore diameter | 57.020-57.038 mm (2.244-2.245 in) |
| Head face flatness | 0.1 mm (0.004 in) maximum overall, 0.05 mm (0.002 in) in any 200 mm x 200 mm (7.87 in x 7.87 in) area |
| 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 | |
| Exhaust valve lift (in @ zero lash) | 7.4 mm (0.2913 in) |
| Intake valve lift (in @ zero lash) | 7.9 mm (0.3110 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 adjustor 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) |
| Cylinder head flatness | 0.08 mm (0.003 in) maximum overall, 0.05 mm (0.002 in) maximum in any 150 mm x 150 mm (6 in x 6 in) area |
| 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 (0.0009 in) |
| Valve stem to guide clearance - exhaust | 0.0029 mm (0.0011 in) |
| Valve face runout | 0.05 mm (0.001 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 | 51.980-52.000 mm (2.046-2.047 in) |
| Production repair | 51.730-51.750 mm (2.036-2.037 in) |
| Main bearing clearance | 0.017-0.047 mm (0.0007-0.0018 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) (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 | 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) |
| (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 SPECIFICATION
All dimensions are in mm unless noted.
TORQUE SPECIFICATION
| Description | Nm | Lb-ft | Lb-in |
|---|---|---|---|
| A/C compressor bolts | 25 | 18 | |
| A/C manifold tube bolt | 20 | 177 | |
| Accessory drive belt tensioner bolt | 50 | 37 | |
| Battery cable nuts | 12 | 106 | |
| Camshaft bearing caps (1) | |||
| Camshaft Position (CMP) sensor bolts | 7 | 62 | |
| Camshaft sprocket bolts | 72 | 53 | |
| Clutch pressure plate bolts | 32 | 24 | |
| Connecting rod bearing cap bolts (1) | |||
| Coolant outlet (front) pipe bolts | 25 | 18 | |
| Coolant outlet pipe bolts | 10 | 89 | |
| Coolant pump bolts | 10 | 89 | |
| Coolant pump pulley bolts | 20 | 177 | |
| Coolant thermostat bolts | 10 | 89 | |
| Coolant tube nuts | 20 | 177 | |
| Crankcase vent oil separator bolts | 10 | 89 | |
| Crankshaft oil seal retainer bolts (1) | |||
| Crankshaft Position (CKP) sensor bolts | 7 | 62 | |
| Crankshaft pulley bolt (1) | |||
| Cylinder block coolant drain plug | 55 | 41 | |
| Cylinder head bolts (1) | |||
| Cylinder Head Temperature (CHT) sensor | 12 | 106 | |
| EGR outlet tube-to-cylinder head fitting | 55 | 41 | |
| EGR outlet tube-to-intake manifold flange bolts | 18 | 159 | |
| EGR tube support bracket bolt | 10 | 89 | |
| EGR valve bolts | 20 | 177 | |
| Engine front cover bolts (1) | |||
| Engine ground cable-to-cylinder head stud bolt | 10 | 89 | |
| Engine lifting eye bolts | 45 | 33 | |
| Engine Oil Pressure (EOP) | 15 | 133 | |
| Engine support insulator-to-crossmember nuts | 103 | 76 | |
| Engine support insulator-to-engine bracket nuts | 102 | 75 | |
| Engine-to-transmission bolts | 48 | 35 | |
| Engine wire harness connector bracket bolt | 10 | 89 | |
| Exhaust manifold-to-cylinder head nuts | 54 | 40 | |
| Exhaust manifold-to-cylinder head studs | 17 | 150 | |
| Exhaust manifold-to-exhaust downpipe flange nuts | 40 | 30 | |
| Flywheel or flexplate bolt (1) | |||
| Fuel rail bolts | 25 | 18 | |
| Generator battery cable nut | 12 | 106 | |
| Generator/A/C compressor support bracket bolts (1) | |||
| Ground strap bolt | 10 | 89 | |
| Ignition coil bolts | 6 | 53 | |
| Intake manifold bolts | 18 | 159 | |
| Knock Sensor (KS) bolt | 20 | 177 | |
| Main bearing beam bolts (1) | |||
| Motor mount bolts | 49 | 36 | |
| Oil drain plug | 28 | 21 | |
| Oil filter adapter bolts | 25 | 18 | |
| Oil level indicator tube bolt | 10 | 89 | |
| Oil pan bolts (1) | |||
| Oil pump assembly bolts (1) | |||
| Oil pump chain tensioner bolts | 10 | 89 | |
| Oil pump pickup tube and screen bolts | 10 | 89 | |
| Oil pump sprocket bolt | 25 | 18 | |
| Oil squirters | 4 | 35 | |
| PCM harness ground cable stud bolt | 10 | 89 | |
| PCM harness retainer nut | 4 | 35 | |
| Power Steering Pressure (PSP) tube nut | 20 | 177 | |
| Power steering pump bolts | 25 | 18 | |
| Solenoid control wire and nut | 6 | 53 | |
| Spark plugs | 12 | 106 | |
| Starter motor bolts | 25 | 18 | |
| Starter wiring harness bolt | 24 | 18 | |
| Throttle Body (TB) shield bolts | 8 | 71 | |
| Timing chain guide bolts | 10 | 89 | |
| Timing chain tensioner bolts | 10 | 89 | |
| Timing peg plug | 20 | 177 | |
| Torque converter-to-flywheel nuts | 35 | 26 | |
| Transmission cooling tubes bracket bolt | 28 | 21 | |
| Transmission dust shield bolts | 10 | 89 | |
| Transmission-to-cylinder block bolts | 48 | 35 | |
| Transmission-to-oil pan bolts | 48 | 35 | |
| Transmission bracket-to-transmission bolts | 90 | 66 | |
| Valve cover bolts (1) | |||
| Wiring harness bracket-to-transmission nut | 10 | 89 | |
| (1) Refer to the appropriate procedure(s). | |||
| (1) | Refer to the appropriate procedure(s). |
TORQUE SPECIFICATION
The 2.3L (140 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 2 coil packs
The 2.3L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a distributorless 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.