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Discussion Starter #1
As title says...........
Next is the later model Duratec:

General Specifications 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)
Belt tension Refer to Section 303-05.
Oil capacity 3.9L + 0.38L (4.1 qt + 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) 7.7 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 lbs)
Intake (valve open) 8.9 mm (0.35 in) of lift 44 kg (97.032 lbs)
Exhaust (valve open) 7.4 mm (0.29 in) of lift 42 kg (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 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)

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


General Specifications Item Specification
Engine
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)
Belt tension Refer to Section 303-05.
Oil capacity 3.9L + 0.38L (4.1 qt + 0.4 qt) with filter
Cylinder Block
Cylinder bore diameter 87.5-87.53 mm (3.444-3.446 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 (0.003 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 (3.4456-3.4460 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 (0.0460-0.0468 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 (0.8265-0.8267 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 (0.30 in)
Valve lift @ zero lash (intake) 7.9 mm (0.31 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 (0.00010 in)
Valve stem-to-guide clearance — exhaust 0.0029 mm (0.00011 in)
Valve face runout 0.05 mm (0.0019 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 0.019-0.035 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 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)

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


General Specifications Item Specification
Motorcraft Metal Surface Cleaner ZC-21 WSE-M5B392-A
Silicone Gasket Remover ZC-30 —
Motorcraft Metal Surface Prep ZC-31 —
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
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 WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) WSS-M97B51-A1
Multi-Purpose Grease XG-4 and/or XL-5 ESB-M1C93-B
Thread Sealant with PTFE TA-24 WSK-M2G350-A2
High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A ESA-M1C198-A
Silicone Brake Caliper Grease and Dielectic Compound XG-3-A ESE-M1C17-A



Torque Specifications Description Nm lb-ft lb-in
Camshaft bearing capsa — — —
Coolant outlet bolts 10 — 89
Cylinder head boltsa — — —
Intake manifold bolts 18 13 —
Flywheel boltsa — — —
Pressure plate bolts 27 20 —
Flexplate boltsa — — —
Torque converter-to-flexplate nuts 35 26 —
Crankshaft pulley bolta — — —
Crankshaft position (CKP) sensora — — —
Crankshaft oil seal retainer boltsa — — —
A/C compressor mounting bolts 25 18 —
A/C manifold tube bolt 21 15 —
Oil drain plug 28 21 —
Oil pan boltsa — — —
Oil pan-to-bellhousing boltsa — — —
Oil level indicator tube bolt(s) 10 — 89
Oil pump screen and cover assembly 10 — 89
Oil pressure sensor 15 11 —
Oil filter adapter bolts 25 18 —
Oil pump-to-engine block boltsa — — —
Oil pump sprocket bolt 25 18 —
Oil pump chain tensioner bolts 10 — 89
Oil pump chain guide bolts 10 — 89
Knock sensor (KS) 20 15 —
Rear transaxle mounting nut 133 98 —
Motor mount nuts 90 66 —
Motor mount bracket bolts 48 35 —
Transaxle roll-restrictor bolts 48 35 —
Engine-to-bellhousing bolts 48 35 —
Starter motor mounting bolts 25 18 —
Starter B+ cable 12 9 —
Starter relay 5 — 44
Coolant pump bolts 10 — 89
Coolant pump pulley bolts 20 15 —
Engine front cover boltsa — — —
Camshaft sprocket bolt 72 53 —
Valve cover boltsa — — —
Engine lifting eye bolts 45 33 —
Exhaust gas recirculation (EGR) valve assembly bolts 20 15 —
EGR tube nut 55 41 —
Valve cover retainers 10 — 89
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 —
Engine-to-bellhousing stud bolt 48 35 —
Engine front cover-to-oil pan boltsa — — —
Power distribution harness eyelet nut 10 — 89
Catalytic converter-to-cylinder head nutsa — — —
Catalytic converter-to-muffler assembly nuts 47 35 —
Catalytic converter support bracket 47 35 —
Catalytic converter heat shield bolts 10 — 89
Generator mounting bolts 25 18 —
Generator heat shield 18 13 —
Generator B+ cable 8 — 71
Generator B+ cable retainer 25 18 —
Radio interference capacitor bracket 10 — 89
Radio interference capacitor ground 10 — 89
Thermostat housing assembly bolts 10 — 89
Coolant expansion tank bolt 10 — 89
Block heater (if equipped) 21 15 —
Power steering pump mounting bolts 25 18 —
Power steering pressure (PSP) tube nut 65 48 —
PSP tube bracket nut 11 8 —
Engine ground cable bolt 48 35 —
Accelerator control snow shield 10 — 89
Timing chain guide bolts 10 — 89
Timing chain tensioner bolts 10 — 89
Engine plug bolt 20 15 —
Crankcase ventilation cover assembly bolts 10 — 89
Air cleaner outlet tube clamps 4 — 35
Accelerator cable bracket 10 — 89
Coil-on-plug retaining bolt 10 — 89
Accessory drive belt tensioner bolt 25 18 —
Accessory drive belt idler bolt 25 18 —
Cylinder head temperature (CHT) sensor 12 9 —
Spark plugs 12 9 —
Fuel rail bolt 25 18 —
Stabilizer bar 55 41 —
Tie-rod end nut 40 30 —
Front brake caliper 28 21 —
Upper strut mount nuts 30 22 —
Suspension arm ball joint bolt 63 46 —
Intermediate shaft bracket-to-engine bolt 40 30 —
Intermediate shaft mounting bracket bolt 25 18 —
Catalytic converter nuts 55 41 —
Catalytic converter heat shield bolts 11 8 —
Catalytic converter support bracket bolts 47 35 —
Catalytic converter-to-exhaust system nuts 47 35 —
 
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