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Old 04-18-2007, 11:21 AM   #1
b16sir1991
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General Specs on the 2.3L Duratec

As title says.....

Third is the 2.3 Duratec:

General Specifications 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) 29-39 psi 200-268 kPa
Belt tension Refer to Section 303-05.
Oil capacity 4.1 qts. + 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) 7.4 mm
Valve lift @ zero lash (intake) 7.9 mm
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) 38.667 lbs.
Intake (valve open) 8.9 mm (0.35 in) of lift 97.032 lbs.
Exhaust (valve open) 7.4 mm of lift 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 (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.)

a No. 3 Journal — Supported by No. 1 and No. 5 journals.


General Specifications Item Specification
Metal Surface Cleaner F4AZ-19A536-RA WSE-M5B392-A
Silicone Gasket and Sealant F7AZ-19554-EA WSE-M4G323-A4
Super Premium SAE 5W-20 Engine Oil XO-5W20-QSP WSS-M2C153-H
MERPOL® O-Ring Seal Lubricant ESE-M99B144-B



Torque Specifications Description Nm lb-ft lb-in
Camshaft bearing capsa — — —
Coolant outlet connection bolts 10 — 89
Oil pan boltsa — — —
Oil pump-to-engine block bolts 25 18 —
Cylinder head boltsa — — —
Intake manifold bolts 18 13 —
Flywheel bolta — — —
Crankshaft pulley bolta — — —
Crankshaft position sensora — — —
Crankshaft oil seal retainera — — —
A/C compressor mounting bolts 25 18 —
Oil pump sprocket bolt 25 18 —
Knock sensor 20 15 —
Engine plug bolt 20 15 —
Rear engine mounting nut 133 98 —
Front engine mounting nuts 80 59
Motor mount bracket bolts 48 35
Engine roll-restrictor bolts 48 35
Engine-to-bellhousing bolts 48 35 —
Torque converter-to-flywheel nuts 35 26 —
Starter motor mounting bolts 25 18 —
Power steering press line tube nut 20 15 —
Powertrain control module (PCM) wiring connector 6 — 53
Coolant pump bolts 10 — 89
Engine front cover boltsa — — —
Camshaft sprocket bolt 72 53 —
Valve cover bolts 10 — 89
Engine lifting eye bolts 45 33 —
Exhaust gas recirculation (EGR) valve assembly bolts 25 18 —
Generator mounting bolts 25 18 —
Thermostat assembly bolts 10 — 89
Oil pump screen and cover assembly 10 — 89
Exhaust manifold studs 17 13 —
Exhaust manifold-to-cylinder head nuts 54 40 —
Coolant pump pulley bolts 25 18 —
Crankshaft position (CKP) sensor boltsa — — —
Generator A/C mounting bracket bolts 48 35 —
Power steering pump mounting bolts 25 18 —
Engine ground cable-to-cylinder head bolt 10 — 89
Oil level indicator tube bolt 10 — 89
Engine wire harness bulkhead connector bolt 10 — 89
Engine body ground bolt 10 — 89
Engine harness ground PCM connector nut 10 — 89
Accelerator control splash shield 8 — 71
Oil pressure sensor 15 11 —
A/C manifold tube bolt 20 15 —
Exhaust manifold-to-exhaust inlet pipe nuts 40 30 —
Transmission tubes bracket bolt 28 21 —
Oil drain plug 28 21 —
Oil pump chain tensioner bolts 10 — 89
Oil pump chain guide bolts 10 — 89
Timing chain guide bolts 10 — 89
Timing chain tensioner bolts 10 — 89
Crankcase ventilation cover assembly bolts 10 — 89
Oil filter adapter bolts 25 18 —
Coolant outlet (front) connector bolts 25 18 —
Air cleaner outlet tube clamps 10 — 89
Accelerator cable bracket 10 — 89
Manifold absolute pressure (MAP) sensor retainer nut 10 — 89
Coil-on-plug retaining bolt 10 — 89
Engine timing plug bolt 20 15 —
Battery tray bolts 12 — 9
Power steering tube bracket nut 13 10 —
Coolant bypass bolt 10 — 89
Belt tensioner bolt 50 37 —
Oil filter cup 33 24 —
Oil pan-to-bellhousing boltsa — — —
Heated oxygen sensor (HO2S) and catalyst monitor sensor wire connector bracket nuts 25 18 —
Bellhousing-to-engine bolts 48 35 —
Bellhousing-to-engine stud bolt 48 35 —
Bellhousing-to-oil pan boltsa — — —
Engine-to-bellhousing stud bolt 48 35 —
Engine front cover-to-oil pan boltsa — — —
Rear main seal mounting plate bolts 10 — 89
Camshaft position (CMP) sensor bolt 7 — 62
Cylinder head temperature (CHT) sensor 12 9 —
Spark plug 15 11 —
Fuel injection supply manifold bolt 18 13 —
Engine vent cover bolt 10 — 89
Pressure plate bolts 32 24 —

Fourth is the SVT:

Engine Data Description 2.0L DOHC 16V
Engine management EEC V/SEFI
Firing order 1-3-4-2
Bore 84.8 mm
Stroke 88.0 mm
Number of main bearings 5
Cubic capacity (cm 3 ) 1,988
Compression ratio 10.2:1
Maximun engine power 170 hp
Maximum engine speed 7,000 rpm
Maximum engine torque at 5,500 rpm 198 lb ft



Engine Oil Viscosity/ambient temperature Description Specification
Recommended engine oil
SAE 5W-30 / below -20°C to over +40°C Engine oil GF3 WSS-M2C915-A

If engine oils of this specification are not available, engine oils of specification API SH/EC, ACEA A2/B2 or ACEA A3/B3 may also be used.




Capacities Litres
Engine oil, initial fill including filter 4.35
Engine oil, oil change including filter 4.25
Engine oil, oil change excluding filter 3.75



Lubricants, Fluids, Sealers and Adhesives Item Specification
Sealant, camshaft bearing caps WSK-M2G348-A5
Sealant, cylinder block mating faces (Hylosil 502) WSK-M4G320-A
Sealant, cylinder block mating faces (Loctite Ultrablack) (alternative) WSE-M4G320-A2
Sealant, crankshaft position sensor ESW-1C155-A
Sealant, crankshaft position sensor (alternative) WSD-M1C-226-A
Sealant, oil pan WSE-M4G323-A6
Thread locking compound SDM-M4G9107-A
Spark plug thread lubricant (Never Seeze) WSD-M13P8-A1
Lubricant, injection nozzle O-rings WSEM-2C903-A1
Silicone grease for spark plug connector seal A696-M1C171-AA
High-temperature grease for clutch disc engagement splines ESD-M1C220-A



Cylinder Block Description mm
Cylinder bore diameter, class 1. 84.800 - 84.810
Cylinder bore diameter, class 2. 84.810 - 84.820
Cylinder bore diameter, class 3. 84.820 - 84.830
Inner diameter, main bearing shells installed 58.011 - 58.038
Inner diameter, main bearing shells installed (main bearing shells with stepped sizes) 58.008 - 58.031
Main bearing radial clearance 0.011 - 0.058
Main bearing radial clearance (main bearing shells with stepped sizes) 0.020 - 0.042
Main bearing parent bore 62.287 - 62.300



Pistons Description mm
Piston diameter, class 1. 84.770 - 84.780
Piston diameter, class 2. 84.780 - 84.790
Piston diameter, class 3. 84.790 - 84.800
Piston clearance in cylinder bore 0.010 - 0.030
Piston ring gaps (installed)
- upper compression ring 0.300 - 0.500
- lower compression ring 0.300 - 0.500
- oil scraper ring 0.400 - 1.400

Ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston This also applies to the oil scraper ring elements. Align the ring gaps at 120 degrees to each other.




Crankshaft Description mm
Main bearing journal diameter 57.980- 58.000
Crankshaft end play 0.090 - 0.260
Connecting rod bearing journal diameter 46.890 - 46.910



Cylinder Block and Lower Crankcase Spacers Description mm
Required spacer thickness if there is a gap between the cylinder block and the lower crankcase of:
0.26 mm - 0.50 mm 0.25
0.51 mm - 0.75 mm 0.50



Connecting Rod Connecting rod mm
Big end bore diameter 49.890 - 49.910
Small end bore diameter 19.951 - 19.981
Inner diameter, connecting rod bearing shells installed 46.926 - 46.960
Radial connecting rod bearing clearance 0.016 - 0.070
Axial connecting rod bearing clearance 0.090 - 0.320



Piston Pin Description mm
Piston pin length 55.800 - 56.200
Piston pin diameter, white 19.997 - 20.000
Piston pin diameter, red 20.625 - 20.628
Piston pin clearance in piston 0.010 - 0.019
Piston pin clearance in connecting rod 0.016 - 0.049



Camshaft Description mm
Bearing journal diameter 25.960 - 25.980
Camshaft bearing radial clearance 0.020 - 0.070
Camshaft end float 0.080 - 0.220



Valves Valves mm
Intake valve clearance in the valve guide 0.017 - 0.064
Exhaust valve clearance in the valve guide 0.017 - 0.064
Intake valve clearance (at 20°C ± 5°C) 0.110 -0.180
Exhaust valve clearance (at 20°C ± 5°C) 0.270 - 0.340



Cylinder Head Cylinder head
Maximum distortion (mating surface) 0.1 mm
Height of mating surface 1.76mm - 2.12 mm
Peak-to-valley height of mating surface (reference length 2.5 mm vertical to groove direction) R 3z = 6.0 μm
Oil pressure at 800 rpm - 850 rpm 1.3 bar - 2.5 bar
Oil pressure at 4000 rpm 3.7 bar - 5.5 bar



Torque Specifications Description Nm lb-ft lb-in
Hose clamps 4 — 35
Intake manifold studs 5 — 44
Intake manifold bolts and nuts 18 13 —
Heat shield to exhaust manifold 10 — 89
Exhaust manifold studs 5 — 44
Exhaust manifold nuts 16 12 —
Exhaust manifold bolts 18 13 —
Catalytic converter to exhaust manifold 48 35 —
Catalytic converter to exhaust 47 35 —
Generator to bracket 25 18 —
Generator bracket to upper cylinder block bolts 25 18 —
Generator bracket to lower cylinder block bolts 65 48 —
Transmission flange bolts 47 35 —
Starter motor to transmission 35 26 —
Flywheel bolts 112 83 —
Clutch pressure plate 29 21 —
Engine roll restrictor to transmission 48 35 —
Engine roll restrictor to subframe 48 35 —
Engine rear mount to body 48 35 —
Engine rear mount (nut on transmission mount bracket) 133 98 —
Engine front mount to engine 80 59 —
Engine front mount to body 48 35 —
Power steering pump bracket 48 35 —
Cylinder head a) — —
Camshaft bearing cap 15 11 —
Cylinder head cover a) — —
Spark plugs 15 11 —
Timing belt tensioner 25 18 —
Camshaft timing belt pulley 68 50 —
Camshaft VCT unit 120 89 —
Camshaft VCT unit plug 38 25 —
Upper timing belt cover 8 — 71
Ignition coil (EI) bracket to cylinder head 21 15 —
Thermostat housing 20 15 —
Fuel rail 10 — 89
Engine rear lifting eye 20 15 —
Engine rear lifting eye studs 7 — 62
Engine front lifting eye 35 26 —
Engine oil drain plug 25 18 —
Oil pressure switch 27 20 —
Cylinder block oil gallery blanking plugs 23 17 —
Heater pipe bracket to oil pan 10 — 89
Oil pan to lower crankcase a) — —
Lower crankcase to cylinder block 30 22 —
Oil pump a) — —
Oil intake pipe to oil pump 10 — 89
Main bearing cap bolts a) — —
Connecting rod bearing cap bolts a) — —
Coolant pump 20 15 —
Rear crankshaft oil seal carrier 20 15 —
Drive belt idler pulley 40 30 —
Crankcase ventilation pipe bracket 23 17 —
Crankcase ventilation 10 — 89
Coolant pump pulley 24 18 —
Crankshaft belt pulley 115 85 —
Crankshaft position sensor bracket 21 15 —
Crankshaft position sensor to bracket 8 — 71
Upper strut mount nuts 30 22 —
Timing belt idler pulley 38 25 —
Knock sensor 20 1
More continued.................


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