SPECIFICATIONS
| Application | Specification |
|---|---|
| Displacement | 144.1 Cu. In. (2.362L) |
| Bore | 3.48 in. (88.5 mm) |
| Stroke | 3.78 in. (96.0 mm) |
| Fuel System | SFI |
GENERAL SPECIFICATIONS
| Application | In. (mm) | |
|---|---|---|
| Cylinder Block | .002 (0.05) | |
| Cylinder Head | ||
| Cylinder Block Side | .0020 (.05) | |
| Manifold Side | .0031 (.08) | |
| Exhaust Manifold | .0276 (0.70) | |
| Intake Manifold | ||
| Air Intake Chamber Side | .0079 (0.20) | |
| Cylinder Head Side | .0031 (0.08) | |
WARPAGE SPECIFICATIONS
| Application | In. (mm) | |
|---|---|---|
| Bearing Center Wall Thickness | ||
| Mark 1 | .0589-.0590 (1.495-1.498) | |
| Mark 2 | .0590-.0591 (1.499-1.501) | |
| Mark 3 | .0591-.0592 (1.502-1.504) | |
| End Play | ||
| Standard | .0020-.0035 (.050-.090) | |
| Wear Limit | .0035 (.090) | |
| Housing Journal Bore Diameter | ||
| Mark 1 | 1.0236-1.0239 (26.000-26.006) | |
| Mark 2 | 1.0239-1.0241 (26.007-26.012) | |
| Mark 3 | 1.0241-1.0243 (26.013-26.018) | |
| Journal Diameter | .9049-.9055 (22.985-23.000) | |
| Oil Clearance | ||
| Standard | .0002-.0012 (.004-.031) | |
| Maximum | .0012 (.031) | |
BALANCE SHAFT
| Application | In. (mm) |
|---|---|
| Intake Valve | .0075-.0114 (.19-.29) |
| Exhaust Valve | .0118-.0157 (.30-.40) |
| (1) Adjust valve clearance with engine cold. | |
| (1) | Adjust valve clearance with engine cold. |
VALVE CLEARANCE SPECIFICATIONS (1)
| Application | In. (mm) | |||
|---|---|---|---|---|
| Crankshaft | ||||
| Crankshaft Bearing Cap Set Bolt | ||||
| Standard | .287-.295 (7.3-7.5) | |||
| Wear Limit | .283 (7.2) | |||
| End Play | ||||
| Standard | .0016-.0094 (.040-.24) | |||
| Wear Limit | .0118 (.30) | |||
| Maximum Runout | .0012 (.03) | |||
| Main Bearings | ||||
| Journal Diameter | (1) | |||
| Journal Out-Of-Round | .0001 (.003) | |||
| Journal Taper | .0001 (.003) | |||
| Oil Clearance | ||||
| Standard Crankshaft Journal | ||||
| Standard | .0007-.0016 (.017-.040) | |||
| Maximum | .0028 (.07) | |||
| Connecting Rod Bearings | ||||
| Journal Diameter | 1.8894-1.8898 (47.99-48.00) | |||
| Journal Out-Of-Round (Maximum) | .0001 (.003) | |||
| Journal Taper | .0001 (.003) | |||
| Oil Clearance | ||||
| Standard Crankshaft Journal | ||||
| Standard | .0007-.0016 (.017-.040) | |||
| Wear Limit | .0028 (.07) | |||
| (1) Main bearing journal diameter is determined by main bearing journal size mark stamped on crankshaft. | ||||
| (1) | Main bearing journal diameter is determined by main bearing journal size mark stamped on crankshaft. |
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
| Application | In. (mm) | |
|---|---|---|
| Connecting Rod Bolt Diameter | ||
| Standard | .283-.287 (7.2-7.3) | |
| Wear Limit | .276 (7.0) | |
| Bore Diameter | ||
| Pin Bushing Bore | .8662-.8665 (22.001-22.010) | |
| Maximum Bend | .002 Per 3.94 (.05 Per 100.0) | |
| Maximum Twist | .0059 Per 3.94 (.150 Per 100.0) | |
| Side Play | ||
| Standard | .0063-.0143 (.160-.362) | |
| Wear Limit | .0143 (.362) | |
CONNECTING RODS
| Application | In. (mm) | |||
|---|---|---|---|---|
| Pistons | ||||
| Clearance | ||||
| Standard | .0020-.0029 (.051-.074) | |||
| Wear Limit | .0039 (.10) | |||
| Diameter | 3.4818-3.4822 (86.835-86.845) | |||
| Pins | ||||
| Pin Diameter | .8660-.8664 (21.997-22.006) | |||
| Piston Fit | (1) | |||
| Rod Fit | ||||
| Standard | .0002-.0004 (.005-.011) | |||
| Wear Limit | .0020 (.051) | |||
| Rings | ||||
| No. 1 | ||||
| End Gap | ||||
| Standard | .0087-.0126 (.22-.32) | |||
| Wear Limit | .0350 (.89) | |||
| Side Clearance | .0012-.0028 (.030-.070) | |||
| No. 2 | ||||
| End Gap | ||||
| Standard | .0197-.0236 (.50-.60) | |||
| Wear Limit | .0531 (1.35) | |||
| Side Clearance | .0012-.0028 (.030-.070) | |||
| No. 3 (Oil) | ||||
| End Gap | ||||
| Standard | .0039-.0138 (.10-.35) | |||
| Wear Limit | .0287 (.73) | |||
| (1) With piston temperature at 176-194°F (80-90°C), piston pin should slide through piston with thumb pressure. | ||||
| (1) | With piston temperature at 176-194°F (80-90°C), piston pin should slide through piston with thumb pressure. |
PISTONS, PINS & RINGS
| Application | In. (mm) | |
|---|---|---|
| Cylinder Bore | ||
| Standard Diameter | 3.4843-3.4848 (88.500-88.513) | |
| Maximum Deck Warpage | .0020 (.051) | |
| Main Bearing Bore I.D. | (1) | |
| (1) Main bearing bore I.D. is determined by main bearing bore size mark on cylinder block. | ||
| (1) | Main bearing bore I.D. is determined by main bearing bore size mark on cylinder block. |
CYLINDER BLOCK
| Application | In. (mm) | |
|---|---|---|
| Body Clearance | ||
| Standard | .004-.0067 (.10-.170) | |
| Wear Limit | .0128 (.325) | |
| Rotor Side Clearance | ||
| Standard | .0012-.0033 (.030-.085) | |
| Wear Limit | .0063 (.16) | |
| Rotor Tip Clearance | ||
| Standard | .0031-.0138 (.080-.350) | |
| Wear Limit | .0138 (.350) | |
OIL PUMP SPECIFICATIONS
| Application | Specification | |
|---|---|---|
| Intake Valves | ||
| Face Angle | 44.5 degrees | |
| Standard Margin | .041-.057 in. (1.05-1.45 mm) | |
| Minimum Margin | .020 in. (.51 mm) | |
| Standard Overall Length | 4.043 in. (101.71) | |
| Minimum Overall Length | 3.823 in. (97.10 mm) | |
| Stem Diameter | .2154-.2159 in. (5.470-5.485 mm) | |
| Exhaust Valves | ||
| Face Angle | 44.5 degrees | |
| Standard Margin | .047-.063 in. (1.2-1.6 mm) | |
| Minimum Margin | .020 in. (.51 mm) | |
| Standard Overall Length | 3.9823 in. (101.15) | |
| Minimum Overall Length | 3.9649 in. (100.7 mm) | |
| Stem Diameter | .2152-.2157 in. (5.465-5.480 mm) | |
| Valve Springs | ||
| Free Length | 1.799 in. (45.7 mm) | |
| Maximum Deviation | .063 in. (1.6 mm) | |
| Maximum Angle (Reference) | 2 degrees | |
VALVES & VALVE SPRINGS
| Application | Specification | |||
|---|---|---|---|---|
| Maximum Warpage | ||||
| Cylinder Block Surface | .0020 in. (.051 mm) | |||
| Intake & Exhaust Manifold Surface | .0031 in. (.078 mm) | |||
| Valve Seats | ||||
| Intake Valve | ||||
| Seat Angle | 45 degrees | |||
| Seat Width | .039-.055 in. (.99-1.40 mm) | |||
| Exhaust Valve | ||||
| Seat Angle | 45 degrees | |||
| Seat Width | .039-.055 in. (.99-1.40 mm) | |||
| Valve Guides | ||||
| Intake Valve | ||||
| Valve Guide Cylinder Head Bore I.D. | ||||
| Standard Valve Guide | .4049-.4057 in. (10.285-10.306 mm) | |||
| Valve Guide I.D. | .2169-.2177 in. (5.51-5.53 mm) | |||
| Valve Guide Installed Protrusion Height | .3779-.3937 in. (9.6-10 mm) | |||
| Valve Stem-To-Guide Oil Clearance | ||||
| Standard | .001-.0024 in. (.025-.060 mm) | |||
| Wear Limit | .0031 in. (.08 mm) | |||
| Exhaust Valve | ||||
| Valve Guide Cylinder Head Bore I.D. | ||||
| Standard Valve Guide | .4049-.4057 in. (10.285-10.306 mm) | |||
| Valve Guide I.D. | .2169-.2177 in. (5.51-5.53 mm) | |||
| Valve Guide Installed Protrusion Height | .3779-.3937 in. (9.6-10 mm) | |||
| Valve Stem-To-Guide Oil Clearance | ||||
| Standard | .0012-.0026 in. (.030-.066 mm) | |||
| Wear Limit | .0039 in. (.099 mm) | |||
CYLINDER HEAD
| Application | In. (mm) | ||
|---|---|---|---|
| End Play | |||
| Intake Camshaft | |||
| Standard | .0016-.0037 (.040-.095) | ||
| Wear Limit | .0043 (.11) | ||
| Exhaust Camshaft | |||
| Standard | .0032-.0053 (.080-.135) | ||
| Wear Limit | .0059 (.15) | ||
| Journal Diameter | |||
| No. 1 Journal | 1.4165-1.4167 (35.971-35.985) | ||
| Other Journal | .9039-.9045 (22.959-22.975) | ||
| Journal Runout | .0012 (.03) | ||
| Lobe Height | |||
| Intake Camshaft | |||
| Standard | 1.8305-1.8345 (46.495-46.595) | ||
| Wear Limit | 1.8262 (46.385) | ||
| Exhaust Camshaft | |||
| Standard | 1.8104-1.8143 (45.983-46.083) | ||
| Wear Limit | 1.8060 (45.873) | ||
| Oil Clearance | |||
| Intake No. 1 With Journal Bearing Mark 1 | |||
| Standard | .0028-.0015 (.007-.038) | ||
| Wear Limit | .0028 (.07) | ||
| Intake No. 1 With Journal Bearing Mark 2 | |||
| Standard | .0031-.0015 (.008-.038) | ||
| Wear Limit | .0028 (.07) | ||
| Intake No. 1 With Journal Bearing Mark 3 | |||
| Standard | .0031-.0015 (.008-.038) | ||
| Wear Limit | .0028 (.07) | ||
| Other Intake Journals | |||
| Standard | .00098-.00244 (.025-.062) | ||
| Wear Limit | .0039 (.10) | ||
| Exhaust No. 1 Journal | |||
| Standard | .00157-.00311 (.040-.079) | ||
| Wear Limit | .0039 (.10) | ||
| Other Exhaust Journals | |||
| Standard | .00098-.00244 (.025-.062) | ||
| Wear Limit | .0039 (.10) | ||
CAMSHAFT
| Application | In. (mm) | |
|---|---|---|
| Bore Diameter | 1.2208-1.2215 (31.009-31.025) | |
| Lifter Diameter | 1.2191-1.2195 (30.966-30.976) | |
| Oil Clearance | ||
| Standard | .0013-.0023 (.033-.059) | |
| Wear Limit | .0028 (.071) | |
VALVE LIFTERS
TORQUE SPECIFICATIONS
| Application | Ft. Lbs (N.m) | |
|---|---|---|
| Balance Shaft Housing-To-Stiffening Crankcase Assembly Bolt | ||
| Step 1 | 16 (22) | |
| Step 2 | (1) | |
| Belt Tensioner Bolt | 44 (60) | |
| Camshaft Bearing Cap Bolt (2) | ||
| No. 1 | 22 (30) | |
| No. 2 | 22 (30) | |
| No. 3 | (5) | |
| Camshaft Timing Sprocket Bolt | 40 (54) | |
| Chain Tensioner Slipper Assembly Bolt | 14 (19) | |
| Connecting Rod Bolt | ||
| Step 1 | 18 (25) | |
| Step 2 | (1) | |
| Coolant Temperature Sensor | 15 (20) | |
| Coolant Pump Pulley Bolt | 19 (26) | |
| Crankshaft Main Bearing Cap Bolt (3) | ||
| Step 1 | 15 (20) | |
| Step 2 | 29 (40) | |
| Step 3 | (1) | |
| Crankshaft Pulley Center Bolt | 125 (170) | |
| Cylinder Block Coolant Drain Cock | 18 (25) | |
| Cylinder Head Bolt (4) | ||
| Step 1 | 58 (79) | |
| Step 2 | (1) | |
| Drain Plug | 36 (49) | |
| Drive Shaft Bearing-To-Cylinder Block Bolt | 47 (64) | |
| Drive Plate-To-Crankshaft Bolt | 72 (98) | |
| Engine Mounting Components | ||
| Engine Hanger No. 1-To-Cylinder Head Bolt | 28 (38) | |
| Engine Hanger No. 2-To-Cylinder Head Bolt | 28 (38) | |
| Engine Moving Control Rod-To-Right Side Engine Mount No. 2 Bolt | 47 (64) | |
| Engine Moving Control Rod W/Bracket-To-Right Fender Apron Bolt | 47 (64) | |
| Front Suspension Brace-To-Body Bolt | 59 (80) | |
| Left Engine Mounting Insulator-To-Automatic Transaxle Bolt | 70 (95) | |
| Left Engine Mounting Insulator-To-Manual Transaxle Bolt | 106 (143) | |
| Rear Engine Mounting Bracket No. 2-To-Lateral Control Rod Bolt (Manual Transaxle) | 69 (89) | |
| Right Side Engine Mounting Insulator-To-Transverse Engine Mounting Bracket Bolt | 70 (95) | |
| Right Side Front Engine Mounting Insulator-To-Right Side Front Engine Mounting Bracket Bolt | 64 (87) | |
| Right Side Engine Mount No. 2-To-Timing Chain Cover Bolt | 38 (52) | |
| Right Side Engine Mounting Stay No. 2-To-Cylinder Head Bolt | 47 (64) | |
| Right Side Engine Mounting Stay No. 2-To-Engine Mount Bracket No. 2 Bolt | 47 (64) | |
| Transverse Engine Mounting Bracket-To-Transfer Case Bolt (4WD) | 25 (34) | |
| Transverse Engine Mounting Bracket-To-Cylinder Block Bolt (4WD) | 54 (40) | |
| Exhaust Components | ||
| Manifold Converter-To-Cylinder Head Bolt | 27 (37) | |
| Exhaust Manifold Stay-To-Manifold Converter | 32 (44) | |
| Flywheel-To-Crankshaft Bolt | 96 (130) | |
| Frame Side Plate-To-Chain Tensioner Bolt | 63 (85) | |
| Frame Side Plate-To-Body Bolt | 24 (32) | |
| Front Axle Hub Nut | 217 (294) | |
| Front Stabilizer Link Assembly | 55 (74) | |
| Front Suspension Arm-To-Lower Ball Joint Bolt | 94 (127) | |
| Front Suspension Member Brace-To-Front Frame Assembly Bolt | 63 (85) | |
| Front Suspension Member Brace-To-Body | 24 (32) | |
| Front Suspension Arm Sub-Assembly Lower No. 1-To-Lower Ball Joint Bolt | 94 (127) | |
| Intake Manifold-To-Cylinder Head | 22 (30) | |
| Knock Sensor | 29 (39) | |
| Oil Control Valve Filter | 22 (30) | |
| Oil Filter Union | 22 (30) | |
| Oil Pan Plug | 18 (25) | |
| Oil Pressure Switch | 11 (15) | |
| Oil Pump Assembly-To-Stiffening Crankcase Bolt | 14 (19) | |
| Oil Pump Drive Sprocket Bolt | 22 (30) | |
| Pipe Plug No. 1-To-Cylinder Block | 19 (26) | |
| Power Steering Gear Assembly Bolt | 52 (70) | |
| Power Steering Pump Bolt | 31 (43) | |
| Propeller Shaft-To-Intermediate Shaft Bolt | 55 (74) | |
| Return Tube Bolt | 15 (20) | |
| Spark Plug | 14 (19) | |
| Stabilizer Bar (Front) | 14 (19) | |
| Starter-To-Cylinder Block Bolt | 29 (39) | |
| Steering Intermediate Shaft Bolt | 26 (35) | |
| Stiffening Crankcase-To-Cylinder Block | 24 (33) | |
| Tie Rod-To-Steering Knuckle Bolt | 36 (49) | |
| Timing Chain Cover Bolts (7) | ||
| Bolt "A" | (5) | |
| Bolt "B" | 15 (20) | |
| Bolt "C" | 32 (43) | |
| Nut | (5) | |
| Torque Converter-To-Drive Plate Bolt | 30 (41) | |
| Transfer Case Fill Plug | 36 (49) | |
| Ventilation Valve | 14 (19) | |
| Wheel Lug Nut | 76 (103) | |
| INCH Lbs (N.m) | ||
| Air Cleaner Assembly Bolt | 44 (5) | |
| Camshaft Position Sensor | 80 (9) | |
| Chain Tensioner Assembly No. 1 Bolt | 80 (9) | |
| Chain Tensioner Plate Bolt | 106 (12) | |
| Chain Vibration Dampener No. 1 Bolt | 80 (9) | |
| Coolant Bypass Pipe-To-Cylinder Block Bolt | 80 (9) | |
| Coolant Inlet Pipe Bolt | 80 (9) | |
| Coolant Pump-To-Cylinder Block Bolt | 80 (9) | |
| Crank Position Sensor Bolt | 80 (9) | |
| Cylinder Head Cover Bolts | 97 (11) | |
| Ignition Coil-To-Cylinder Head Bolt | 80 (9) | |
| Manifold Converter Insulator No. 1-To-Manifold Converter | 106 (12) | |
| Oil Cooler Pipe | 80 (9) | |
| Oil Level Gage Guide Bolt | 80 (9) | |
| Oil Pan-To-Stiffening Crankcase Assembly Bolt | 80 (9) | |
| Speed Sensor Bolt | 71 (8) | |
| Stud Bolt (6) | ||
| Stud A (M16) | 44 (5) | |
| Stud B (M10) | 89 (10) | |
| Stud C (M6) | 44 (5) | |
| Timing Chain Guide Bolt | 80 (9) | |
| Timing Chain Guide Cover Bolt | 80 (9) | |
| Wheel Speed Sensor (Front) Bolt | 71 (8) | |
| (1) Tighten an additional 90 degrees. (2) Tighten to specification in sequence. (Scheme 45) (3) Tighten to specification in sequence. (Scheme 46) (4) Tighten to specification in sequence. (Scheme 47) (5) Tighten to 80 INCH Lbs. (9 N.m). (6) Tighten to specification. (Scheme 48) (7) Tighten to specification in sequence. (Scheme 49) | ||
| (1) | Tighten an additional 90 degrees. |
| (2) | Tighten to specification in sequence. (Scheme 45) |
| (3) | Tighten to specification in sequence. (Scheme 46) |
| (4) | Tighten to specification in sequence. (Scheme 47) |
| (5) | Tighten to 80 INCH Lbs. (9 N.m). |
| (6) | Tighten to specification. (Scheme 48) |
| (7) | Tighten to specification in sequence. (Scheme 49) |
TORQUE SPECIFICATIONS
