ITEM SPECIFICATION
| 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® Specialty Orange Engine Coolant with Bittering Agent (US); Motorcraft® Specialty Orange Engine Coolant (Canada) VC-3-B (US); CVC-3-B (Canada); or equivalent | WSS-M97B44-D | |
| 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 | WSSM-2C930-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 |
ITEM SPECIFICATION
| 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) |
| 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 | 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 | |
| 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 (0.0001 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 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 | 0.017-0.047 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. |
ITEM SPECIFICATION
TORQUE SPECIFICATIONS
| Description | N.m | Lb-ft | Lb-in |
|---|---|---|---|
| Accessory drive belt idler pulley bolt | 25 | 18 | |
| Accessory drive belt splash shield bolts | 9 | 80 | |
| A/C compressor bolts and stud bolt | 25 | 18 | |
| A/C compressor tube bracket nuts | 10 | 89 | |
| A/C tube-to-compressor nut | 15 | 133 | |
| Bellhousing-to-engine bolts | 48 | 35 | |
| Bellhousing-to-engine stud bolt | 48 | 35 | |
| Bellhousing-to-oil pan bolts | 48 | 35 | |
| Camshaft bearing caps (1) | |||
| Camshaft drive gear bolts | 72 | 53 | |
| Connecting rod bearing cap bolts (1) | |||
| Coolant degas bottle bolt | 8 | 71 | |
| Coolant outlet bolts | 10 | 89 | |
| Coolant pump bolts | 10 | 89 | |
| Coolant pump pulley bolts | 20 | 177 | |
| Crankshaft rear seal with retainer plate bolts (1) | |||
| Crankshaft Position (CKP) sensor bolts (1) | |||
| Crankshaft pulley bolt (1) | |||
| Crankcase vent oil separator bolts | 10 | 89 | |
| 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 lower timing hole plug | 12 | 106 | |
| Engine front cover-to-oil pan bolts | 10 | 89 | |
| Engine front cover upper timing hole plug | 10 | 89 | |
| Engine ground wire bolt | 48 | 35 | |
| Engine lifting eye bolts | 45 | 33 | |
| Engine mount bolts | 48 | 35 | |
| Engine mount nuts | 90 | 66 | |
| Engine Oil Pressure (EOP) switch | 15 | 133 | |
| Engine oil filter (2) | |||
| Engine plug bolt | 20 | 177 | |
| Engine-to-bellhousing bolts | 48 | 35 | |
| Engine-to-bellhousing stud bolt | 48 | 35 | |
| Exhaust manifold heat shield bolts | 10 | 89 | |
| Exhaust manifold nuts (1) | |||
| Exhaust manifold studs | 17 | 150 | |
| Flexplate bolts (1) | |||
| Fuel rail bolt | 25 | 18 | |
| Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector bracket nuts | 25 | 18 | |
| Ignition coil-on-plug bolts | 10 | 89 | |
| Intake manifold bolts | 18 | 159 | |
| Intermediate shaft bracket bolts | 48 | 35 | |
| Knock Sensor (KS) | 20 | 177 | |
| Lifting eye bolts | 45 | 33 | |
| Main bearing beam bolts (1) | |||
| Negative battery cable ground bolt | 10 | 89 | |
| Negative battery terminal ground wire nut | 10 | 89 | |
| Oil cooler bolt | 34 | 25 | |
| Oil filter adapter bolts | 25 | 18 | |
| Oil level indicator tube bolt | 10 | 89 | |
| Oil pan drain plug | 28 | 21 | |
| Oil pan bolts (1) | |||
| Oil pan-to-bellhousing bolts | 48 | 35 | |
| Oil pump drive chain tensioner shoulder bolt | 10 | 89 | |
| Oil pump drive chain tensioner 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 | |
| Positive battery cable nut | 10 | 89 | |
| Power steering tube bolt | 18 | 159 | |
| Power steering tube bracket nut | 20 | 177 | |
| Power steering tube clip bolt | 10 | 89 | |
| Radio interference capacitor bracket bolt | 10 | 89 | |
| Radio interference capacitor ground bolt | 10 | 89 | |
| Spark plugs | 12 | 106 | |
| Starter motor bolt | 35 | 26 | |
| Starter motor stud bolt | 35 | 26 | |
| Starter relay large nut | 12 | 106 | |
| Starter relay small nut | 5 | 44 | |
| Thermostat housing bolts | 10 | 89 | |
| Timing chain guide bolts | 10 | 89 | |
| Timing chain tensioner bolts | 10 | 89 | |
| Torque converter-to-flexplate nuts | 35 | 26 | |
| Transaxle mounting nut mount plate center nut | 150 | 111 | |
| Transaxle mounting nut mount plate outer nuts | 48 | 35 | |
| Transaxle roll-restrictor bolts | 70 | 52 | |
| Valve cover bolts (1) | |||
| Wiring harness bracket bolts | 10 | 89 | |
| (1) See procedure for specification. (2) 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) | Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter. |
TORQUE SPECIFICATIONS
The 2.0L 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 2.0L 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.