Engine Mechanical - 4.0L (Unit Repair): Specifications — Engine Mechanical - 4.0L (Unit Repair) — Mechanical

Fastener Tightening Specifications

Application		Specification
Application		Metric	English
Accelerator Control Cable Bracket Bolt		9 N.m	80 lb in
Air Conditioning Compressor
Front Bolt (In Sequence)		50 N.m	37 lb ft
Front Nut (In Sequence)		50 N.m	37 lb ft
Mounting Stud to Block		25 N.m	18 lb ft
Side Lower Bolt (In Sequence)		25 N.m	18 lb ft
Side Upper Bolt (In Sequence)		50 N.m	37 lb ft
A.I.R. Valve Bracket
Bolt		9 N.m	80 lb in
Nut		9 N.m	80 lb in
Camshaft Bearing Cap Bolt		12 N.m	106 lb in
Camshaft Cover Bolt		10 N.m	89 lb in
Camshaft Drive Chain Guide Access Plug		4,5 N.m	39 lb in
Camshaft Intermediate Drive Shaft
Bolt		10 N.m	89 lb in
Sprocket Bolt		60 N.m	44 lb ft
Camshaft Position Sensor Bolt		10 N.m	89 lb in
Camshaft Seal Retainer Bolt		3 N.m	27 lb in
Camshaft Sprocket Bolt		120 N.m	89 lb in
Connecting Rod Bolt
First Pass		30 N.m	22 lb ft
Second Pass		Back off to zero
Third Pass		25 N.m	18 lb ft
Final Pass		+110 degrees
Crankshaft Balancer Bolt
First Pass		50 N.m	37 lb ft
Final Pass		+ 120 degrees
Crankshaft Position Sensor Bolt		10 N.m	89 lb in
Cylinder Head Bolt (M11)
First Pass		40 N.m	30 lb ft
Second Pass		+70 degrees
Third Pass		+60 degrees
Final Pass		+60 degrees (190 degrees Total)
Cylinder Head Bolt (M6)		12 N.m	106 lb in
Drive Belt
Idler Pulley Bolt		50 N.m	37 lb ft
Tensioner Bolt		50 N.m	37 lb ft
ECT Sensor		20 N.m	15 lb ft
EGR Tube
Bolt		24 N.m	18 lb ft
Nut		60 N.m	44 lb ft
EGR Valve
Bolt		28 N.m	21 lb ft
Bracket Shield Nut		10 N.m	89 lb in
Engine Coolant Outlet Fitting		47 N.m	35 lb ft
Engine Flywheel Bolt
First Pass		15 N.m	11 lb ft
Final Pass		+50 degrees
Engine Front Cover Bolt (In Sequence)		10 N.m	89 lb in
EVAP Emission Canister Purge Valve Bolt		10 N.m	89 lb in
Exhaust Manifold
Bolt		25 N.m	18 lb ft
Flange Bolt		25 N.m	18 lb ft
Nut		25 N.m	18 lb ft
Front Intermediate Pipe
Bolt		30 N.m	22 lb ft
Stud		30 N.m	22 lb ft
Fuel Rail
Stud		9 N.m	80 lb in
Bracket Nut		9 N.m	80 lb in
Generator
Front Lower Bolt		50 N.m	37 lb ft
Front Upper Bolt		50 N.m	37 lb ft
Side Front Bolt		50	37 lb ft
Side Rear Bolt		50 N.m	37 lb ft
Ignition Coil Assembly Bolt (In Sequence)		9 N.m	80 lb in
Intake Manifold Bolt		10 N.m	89 lb in
Knock Sensor Bolt		20 N.m	15 lb ft
Lift Bracket
Left Rear Lift Bracket Bolt (to Water Crossover)		24 N.m	17 lb ft
Right Rear Lift Bracket Bolt (to Cylinder Head)		47 N.m	35 lb ft
Lower Crankcase
Bearing Bolt
	M10 x 1.5 First Pass (In Sequence)	20 N.m	15 lb ft
	M10 x 1.5 Final Pass (In Sequence)	+65 degrees
Perimeter Bolt
	M8 x 1.25 (In Sequence)	30 N.m	22 lb ft
Oil Cooler Line Connector Fittings		18 N.m	13 lb ft
Oil Filter Adapter
Oil Filter Bypass Hole Plug		20 N.m	15 lb ft
Oil Filter Fitting		29 N.m	21 lb ft
Oil Cooler Bypass Hole Plug		20 N.m	15 lb ft
Oil Level Indicator Tube Nut		10 N.m	89 lb in
Oil Level Sensor		20 N.m	15 lb ft
Oil Manifold Plate Bolt		10 N.m	89 lb ft
Oil Pan Bolt		10 N.m	89 lb ft
Oil Pan Brace		50 N.m	37 lb ft
Oil Pan Drain Plug		20 N.m	15 lb ft
Oil Pressure Switch		16 N.m	12 lb ft
Oil Pump
Cover Bolt		12 N.m	106 lb in
Mounting Bolt First Pass		10 N.m	89 lb in
Mounting Bolt Final Pass		+35 degrees
Pick-Up Tube Bolt		24 N.m	18 lb ft
Pick-Up Tube Nut		10 N.m	89 lb in
Oxygen Sensor		40 N.m	30 lb ft
Plenum Duct Clamp		2.25 N.m	20 lb in
Power Steering Pump Bolt		25 N.m	18 lb ft
Primary Camshaft Drive Chain
Guide Bolt		25 N.m	18 lb ft
Tensioner Bolt		25 N.m	18 lb ft
Secondary Camshaft Drive Chain
Guide Bolt		25 N.m	18 lb ft
Shoe Bolt		25 N.m	18 lb ft
Tensioner Bolt		25 N.m	18 lb ft
Spark Plug		15 N.m	11 lb ft
Starter Motor Bolt		30 N.m	22 lb ft
Throttle Body Bolt		10 N.m	89 lb in
Water Crossover Bolt and Stud		25 N.m	18 lb ft
Water Outlet Bolt		10 N.m	89 lb in
Water Pump		100 N.m	74 lb ft
Water Pump Cover Bolt		10 N.m	89 lb in
Water Pump Drive Belt
Shield Bolt		10 N.m	89 lb in
Shield Nut		10 N.m	89 lb in
Tensioner Bolt		10 N.m	89 lb in
Water Pump Pulley Cap		2 N.m	18 lb in

FASTENER TIGHTENING SPECIFICATIONS

Engine Mechanical Specifications

Application		Specification
Application		Metric	English
General
	Engine Type	V-8
	Displacement	4.0 Liter	244 cu in
	RPO	L47
	VIN	C
	Compression Ratio	100:1
	Compression Pressure at Cranking Speed, Throttle Open	965-1172 KPa	140-170 psi
	Power	186.5 kW @ 5,600 RPM	250 hp @ 5,600 RPM
	Torque	352.5 N.m @ 4,000 RPM	260 lb ft @ 4,000 RPM
	Firing Order	1-2-7-3-4-5-6-8
Bearings
	Crankshaft, Main, Bearing Material	Aluminum
	Production Clearance	0.015-0.055 mm	0.0006-0.0022 in
	Service - Maximum	0.0635 mm	0.0025 in
	Connecting Rod Bearing Material	Aluminum
	Production Clearance	0.025-0.076 mm	0.0010-0.0030 in
	Service - Maximum	0.076 mm	0.0030 in
Camshaft
	Camshaft Material	Hardened Cast Gray Iron
	Bearing Number	5
	Bearing Number on Left Cylinder Head Intake	6
	Bearing Journal Diameter	26.948-26.972 mm	1.0610-1.0619 in
	Bearing Bore Diameter, In Cylinder Head	27.013-27.033 mm	1.0635-1.0642 in
	Bearing Clearance	0.051-0.076 mm	0.0020-0.0030 in
	Production Limits	0.040-0.090 mm	0.0016-0.0035 in
	Service Limits - Maximum	0.090 mm	0.0035 in
	Runout	0.050 mm	0.0020 in
	Out-of-Round	0.006 mm	0.0002 in
	Straightness	0.007 mm	0.0003 in
	Thrust Width	22.990-23.090 mm	0.9051-0.9091 in
	Timing, @ 0.150 mm Lift, Intake Opens	5.6 degrees BTDC
	Intake Centerline	113 degrees ABDC
	Intake Closes	236.8 degrees ABDC
	Exhaust Opens	222.5 degrees BTDC
	Exhaust Centerline	107 degrees BTDC
	Exhaust Closes	13.8 degrees ABDC
	Camshaft Lift, Intake	6.15 mm	0.2421 in
	Exhaust	5.94 mm	0.2339 in
	Valve Intake	10.500 mm	0.4134 in
	Exhaust	10.000 mm	0.3937 in
	Duration, @ 0.150 mm Lift, Intake	242 degrees
	Exhaust	236 degrees
	Valve Overlap, @ 0.150 mm Lift	1.98 degrees
	Left Intake Water Pump Drive End, Diameter	15.852-15.902 mm	0.6241-0.6261 in
	Diameter Within Last 19.5 mm (0.7677 in)	15.872-15.882 mm	0.6249-0.6253 in
	Runout	0.150 mm	0.0059 in
Camshaft Drive
	Primary Drive Type	Endless Chain
	Adjustment	Hydraulic, Automatic
	Pitch	8 mm	0.315 in
	Width	Single Row
	Secondary Drive Type	Endless Chain
	Adjustment	Hydraulic, Automatic
	Pitch	8 mm	0.315 in
	Width	Single Row
Connecting Rods
	Diameter, Crankshaft End, Without Bearings	57.136-57.152 mm	2.2495-2.2501 in
	Taper, Maximum	0.005 mm	0.0002 in
	Piston Pin End, With Bushing	21.002-21.016 mm	0.8268-0.8274 in
	Taper, Maximum	0.007 mm	0.0003 in
	Without Bushing	23.453-23.493 mm	0.9234-0.9421 in
	Width	21.774 mm	0.8572 in
	Center to Center	151.000 mm	5.9449 in
	Side Clearance, Pair of Connecting Rods on Crankpin	0.200-0.500 mm	0.0079-0.0197 in
Crankshaft
	Journals Crankshaft, Main, Diameter	64.350-64.366 mm	2.5335-2.5341 in
	Runout #1, #5	0.022 mm	0.0009 in
	Runout #2, #3, #4	0.025 mm	0.0010 in
	Round	0.005 mm	0.0002 in
	Taper	0.005 mm	0.0002 in
	Width, #1, #2, #4, #5	24.540-24.660 mm	0.9661-0.9709 in
	Thrust #3, Wall Width	25.150-25.250 mm	0.9902-0.9941 in
	Runout	0.040 mm	0.0016 in
	Square	0.010 mm	0.0004 in
	Crankpin, Connecting Rod, Diameter	53.947-53.963 mm	2.1239-2.1245 in
	Round	0.005 mm	0.0002 in
	Taper	0.005 mm	0.0002 in
	Width	43.840-43.960 mm	1.7260-1.7307 in
	End Play, Production	0.050-0.500 mm	0.0020-0.0197 in
	Service - Maximum	0.500 mm	0.0197 in
	Flange, Engine Flywheel, Face Runout	0.025 mm	0.0010 in
	Rear Seal, Diameter	95.880-95.980 mm	3.7748-3.7787 in
	Runout	0.025 mm	0.0010 in
	Nose Diameter, 0.0-21.0 mm, From Front Face	34.500-34.750 mm	1.3583-1.3681 in
	Runout	0.100 mm	0.0039 in
	21.0-53.00 mm, From Front Face	34.892-34.912 mm	1.3737-1.3745 in
	Runout	0.030 mm	0.0012 in
	53.00 mm, From Front Face, to Rolled Fillet	33.450-33.550 mm	1.3169-1.3209 in
	Runout	0.100 mm	0.0039 in
	89.94-110.54 mm, From Front Face	44.950-45.000 mm	1.7697-1.7717 in
	Runout	0.025 mm	0.0010 in
Crankshaft Balancer
	Hub Inside Diameter	34.847-34.864 mm	1.3719-1.3726 in
	Outside Diameter, Without Wear Sleeve	50.730-50.870 mm	1.9972-2.0028 in
	Runout	0.100 mm	0.0039 in
Cylinder Block
	Material	Aluminum with Cast-in Gray Iron Sleeves
	Length	528.45 mm	20.8100 in
	Cylinder Bore Diameter @ 41 mm (1.6100 in) Below Deck Face	86.992-87.008 mm	3.4249-3.4255 in
	Out-of-Round, Production	0.010 mm	0.0004 in
	Service - Maximum Allowed	0.100 mm	0.0039 in
	Taper, Production	0.010 mm	0.0004 in
	Service - Maximum Allowed	0.100 mm	0.0039 in
	Piston Clearance @ 41 mm (1.6100 in) Below Deck Face	0.020-0.051 mm	0.0008-0.0020 in
	Stroke	84 mm	3.3071 in
	Deck Height	224.55 mm	8.8406 in
	Clearance - Above Deck Surface	0.45 mm	0.0177 in
	Face Flatness - Maximum Allowed	0.100 mm	0.0039 in
	Crankshaft Bearing Bore, Mains, Diameter	72.430-72.442 mm	2.8516-2.8521 in
	Crankshaft Rear Seal Bore, Diameter	115.962-116.038 mm	4.5654-4.5684 in
	Runout - Maximum Allowed	0.250 mm	0.0098 in
Cylinder Head
	Type	DOHC - 4 Valves Per Cylinder
	Material	Aluminum
	Chamber Depth to Surface	10.470-10.710 mm	0.4122-0.4217 in
	Flatness, Without Resurfacing - Maximum	0.050 mm	0.0020 in
	Resurfacing Amount - Maximum	0.200 mm	0.0079 in
	Distance to Camshaft Bore Centerline	136.000 mm	5.3543 in
	Inside Diameter	5.969-5.989 mm	0.2350-0.2358 in
	Valve Guide-to-Valve Stem Clearance Production, Exhaust	0.050-0.100 mm	0.0020-0.0039 in
	Intake	0.028-0.068 mm	0.0011-0.0027 in
	Service, Exhaust	0.120 mm	0.0047 in
	Intake	0.110 mm	0.0043 in
	Valve Seating Surface, Angle	45.75 degrees
	Width, Exhaust	1.300-1.700 mm	0.0512-0.0669 in
	Intake	0.420-0.820 mm	0.0165-0.0323 in
	Runout - Maximum	0.050 mm	0.0020 in
	Relief, Angle	20 degrees
	Width, Exhaust	0.160-0.360 mm	0.0063-0.0142 in
	Intake	0.110-0.310 mm	0.0043-0.0118 in
	Runout - Maximum	0.050 mm	0.0020 in
	Undercut Angle, Exhaust	65 degrees
	Intake	60 degrees
Oil System
	Oil Pump Type	Gerotor
	Minimum Pressure at Normal Operating Temperature @ Idle	35 kPa	5 psi
	Minimum Pressure at Normal Operating Temperature @ 2,000 RPM	250 kPa	35 psi
	Oil Pressure Recirculation	Internal Piston Valve
	Oil Filter Type	PF 58
	Oil Capacity with Filter	7.098 Liter	7.5 Quarts
	Without Filter	6.625 Liter	7.0 Quarts
Pistons
	Material	Aluminum
	Diameter	86.977-86.962 mm	3.4243-3.4237 in
	Taper	No Taper Measurement
	Pin Bore Diameter	21.003-21.008 mm	0.8269-0.8271 in
	Ring Groove Width, 1st Compression, Top	1.230-1.255 mm	.0484-0.0494 in
	2nd Compression	1.530-1.555 mm	0.0602-0.0612 in
	Oil Control	2.530-2.555 mm	0.0996-0.1006 in
	Inside Diameter, 1st Compression, Top	79.540-79.790 mm	3.1315-3.1413 in
	2nd Compression	77.270-77.520 mm	3.0421-3.0520 in
	Oil Control	79.680-79.930 mm	3.1370-3.1468 in
Piston Pins
	Material	Steel
	Diameter	20.995-21.000 mm	0.8266-0.8268 in
	Length	62.000-61.500 mm	2.4409-2.4212 in
	Retention	Snap Rings (2)
Piston Rings
	Compression	2
	Oil Ring	1
	Side Clearance, 1st Compression, Top	0.040-0.095 mm	0.0016-0.0037 in
	2nd Compression	0.040-0.095 mm	0.0016-0.0037 in
	Oil Control	None - Side Sealing
	Ring End Gap, 1st Compression, Top	0.250-0.400 mm	0.0098-0.0157 in
	2nd Compression	0.350-0.050 mm	0.0138-0.0020 in
	Oil Control	0.250-0.760 mm	0.0098-0.0299 in
Rocker Arms, Followers
	Type	Roller
	Ratio	1.68 to 1
	Roller Diameter	17.740-17.800 mm	0.6984-0.7008 in
Valves
	Exhaust, Length from Tip to Face OD	91.730-91.990 mm	3.6114-3.6217 in
	Head, Diameter	27.880-28.140 mm	1.0976-1.1079 in
	Runout - Maximum	0.380 mm	0.0150 in
	Chamfer, Angle	30 degrees
	Width - Minimum	0.380 mm	0.0150 in
	Margin Width	1.070 mm	0.0421 in
	Face, Angle	45 degrees
	Width - Minimum	1.500 mm	0.0591 in
	Runout - Maximum	0.038 mm	0.0015 in
	Valve Stem Diameter	5.920-5.940 mm	0.2331-0.2339 in
	Out-of-Round - Maximum Deviation	0.008 mm	0.0003 in
	Straightness - Maximum Deviation	0.013 mm	0.0005 in
	Intake, Length from Tip to Face OD	110.600-110.860 mm	4.3543-1.3646 in
	Head Diameter	34.090-34.350 mm	1.3421-1.3524 in
	Runout - Maximum	0.380 mm	0.0150 in
	Chamfer, Angle	30 degrees
	Width - Minimum	0.380 mm	0.0150 in
	Margin Width	0.890 mm	0.0350 in
	Face, Angle	45 degrees
	Width - Minimum	1.000 mm	0.0394 in
	Runout - Maximum	0.038 mm	0.0015 in
	Valve Stem Diameter	5.920-5.940 mm	0.2331-0.2339 in
	Out-of-Round - Maximum Deviation	0.008 mm	0.0003 in
	Straightness - Maximum Deviation	0.013 mm	0.0005 in
Valve Lifters, Stationary Hydraulic Lifter Adjuster - SHLA
	Type	Stationary Hydraulic
	Diameter	11.986-12.000 mm	0.4719-0.4724 in
	Lifter Bore Diameter, In Cylinder Head	12.013-12.037 mm	0.4730-0.4739 in
	Clearance	0.037-0.041 mm	0.0015-0.0016 in
Valve Springs
	Length Installed	35 mm	1.3780 in
	Free	40.790-43.690 mm	1.6059-1.7201 in
	Valve Closed	35 mm	1.3780 in
	Valve Open	24.500 mm	0.9646 in
	Force, Valve Closed	211.4-233.4 N	47.5-52.5 lb
	Valve Open	579.0-631.0 N	130.2-141.9 lb
	Diameter Inside	17.750-18.250 mm	0.6988-0.7185 in
	Outside	26.23 mm	1.0327 in
	Wire, Ovate	4.110 x 3.280 mm	0.1618 x 0.1291 in
	Coil Direction	Clockwise
	Total Number of Coils	6.90-7.10
	Identifier	Orange