GENERAL SPECIFICATIONS
DISPLACEMENT 2.3L
NUMBER OF CYLINDERS 4
BORE AND STROKE 3.780 x 3.126
FIRING ORDER 1-3-4-2
OIL PRESSURE (Hot @ 2000 prm) 40-60
DRIVE BELT TENSION (1)
CYLINDER HEAD AND VALVE TRAIN
COMBUSTION CHAMBER VOLUME (cc) 59.55-62.55
VALVE GUIDE BORE DIAMETER 0.3433-0.3443
VALVE SEATS
Intake 0.060-0.080
Exhaust 0.070-0.090
Service Clearance Limit 45°
RUNOUT LIMIT (T.I.R. Max) 0.0016
VALVE ARRANGMENT (Front to Rear) E-I-E-I-E-I-E-I
VALVE LASH ADJUSTER BORE TEMPERATURE 0.8430-0.9449
Valve Stem To Guide Clearance
Intake 0.0010-0.0027
Exhaust 0.0015-0.0032
Service Clearance Limit 0.0055 Max.
VALVE HEAD DIAMETER
Intake 1.730-1.740
Exhaust 1.49-1.51
Valve Face Runout Limit 0.002 Max.
VALVE FACE ANGLE LIMIT 44°
VALVE STEM DIAMETER (Standard)
Intake 0.3516-0.3423
Exhaust 0.3411-0.3418
(0.015 Oversize)
Intake 0.3566-0.3573
Exhaust 0.3461-0.3568
(0.030 Oversize)
Intake 0.3716-0.3723
Exhaust 0.3711-0.3718
VALVE SPRINGS
Compression Pressure (Lb. @ Spec. Length)
Intake and Exhaust (Installed Load) 71-79 @ 1.52
Exhaust and Intake Valve
Turbo (Closed) 71.3 - 78.7 lbs. @ 1.52 (317 - 350 newtons @ 38.61mm)
(Open) 151.9 - 165.9 lbs. @ 1.12 (676 - 738 newtons @ 28.45mm)
Free Length (Approximate) 1.877
Assembled Height 1-17/32" -1-19/32"
Service Limit 5% Pressure Loss @ Specified Length
Out of Square Service Limit 5/64 (0.078)
ROCKER ARM (Cam Follower)
Ratio 1.4-1.6:1
VALVE TAPPET, LIFTER OR ADJUSTER
Diameter (Standard) 0.8422-0.8427
Clearance-to-Bore 0.0007-0.0027
Service Limit 0.005 Max.
Hydraulic Leakdown Rate (2) 2.8 seconds
Collapsed Tappet Gap
Allowed 0.035-0.055 @ Cam
Desired 0.040-0.050 @ Cam
CAMSHAFT
LOBE LIFT
Intake 0.400
Exhaust 0.400
Allowable Lobe Lift Loss 0.005 Max.
THEORETICAL VALVE LIFT @ ZERO LASH
Intake 0.390
Exhaust 0.390
END PLAY 0.001-0.007
Service Limit 0.009
JOURNAL-TO-BEARING CLEARANCE 0.001-0.003
Service Limit 0.006
JOURNAL DIAMETER
#1 1.7713-1.7720
#2 1.7713-1.7720
#3 1.7713-1.7720
#4 1.7713-1.7720
RUNOUT LIMIT 0.005 Max T.I.R.
Out-of-Round Limit 0.0005 in. Max.
Front Bearing Location (3) 0.000-0.010
CYLINDER BLOCK
HEAD GASKET SURFACE FLATNESS 0.003 in any 6" -).006 overall
HEAD GASKET SURFACE FINISH (RMS) 60-150
MAIN BEARING BORE DIAMETER 2.5902-2.5910
DISTRIBUTOR SHAFT BEARING BORE DIAMETER 0.5155-0.5170
CRANKSHAFT, FLYWHEEL AND CONNECTING ROD
MAIN BEARING JOURNAL DIAMETER 2.399-2.3982
Out-of-Round Limit 0.0006 Max.
Taper Limit 0.0006 per inch
Journal Runout Limit 0.002 Max.
Surface Finish (RMS) 12 Max
Runout Service Limit 0.005
THRUST BEARING JOURNAL
Length 1.2010-1.1990
CONNECTING ROD JOURNAL
Diameter 2.0465-2.0472
Out-of-Round Limit 0.0006 Max.
Taper Limit 0.0006 per inch Max.
Surface Finish (RMS) 12 Max.
MAIN BEARING THRUST FACE
Surface Finish (RMS) 35 Front 25 Rear (Max.)
Runout Limit 0.001 Max.
FLYWHEEL CLUTCH FACE
Runout Limit 0.005
FLYWHEEL RING GEAR LATERAL RUNOUT (T.I.R.)
Standard Transmission 0.025
Automatic Transmission 0.060
CRANKSHAFT FREE END PLAY LIMIT 0.004-0.008
Service Limit 0.012
AUXILIARY SHAFT END PLAY 0.001-0.007
CONNECTING ROD BEARINGS
Clearance Crankshaft --Desired 0.0008-0.0015
--Allowable 0.0008-0.0026
Bearing Wall Thickness (Standard) (4) 0.0619-0.0624
MAIN BEARINGS
Clearance Crankshaft --Desired 0.0008-0.0015
--Allowable 0.0008-0.0026
Bearing Wall Thickness (Standard) (4) 0.0956-0.0951
AUXILIARY SHAFT BEARINGS
Clearance to Shaft 0.0006-0.0026
CONNECTING ROD
Piston Pin Bore Diamater 0.9096-0.9012
Crankshaft Bearing Bore Diameter 2.1720-2.1728
Out-of-Round Limit 0.0004
Taper Limit 0.0004
Length (Center-to-Center) 5.2031-5.2063
Alignment (Bore-to-Bore Max. Difference) (5)
Twist 0.024
Bend 0.012
Side Clearance (Assembled to Crank)
Standard 0.0035-0.0105
Service Limit 0.014
CYLINDER BORE AND PISTON
CYLINDER BORE
Diameter 3.7795-3.7825
Surface Finish (CLA) 8-24
Out-of-Round Limit 0.0015
Out-of-Round Service Limit 0.005
Taper Service Limit 0.010
Piston-to-Bore Clearance (Select Fit) 0.0030-0.0038
SERVICE PISTON SELECTION (6)
Piston Bore Diameter Code-Service Piston Required
3.7764-3.7770 RED
3.7776-3.7782 BLUE
Pin Bore Diameter 0.9123-0.9126
Ring Groove Width
Compression (Top) 0.080-0.081
Compression (Bottom) 0.080-0.081
Oil 0.188-0.189
PISTON PIN
Length 3.010-3.040
Diameter
Standard 0.9118-0.9124
0.001 Oversize 0.9130-0.9133
0.002 Oversize 0.9140-0.9143
Piston-to-Pin Clearance 0.0003-0.0005
Pin-to-Rod Clearance Interference Fit
PISTON RINGS
Ring Width
Compression (Top) 0.077-0.078
Compression (Bottom) 0.077-0.078
Side Clearance
Compression (Top) 0.002-0.004
Compression (Bottom) 0.002-0.004
Ring Gap
Compression (Top) 0.010-0.020
Compression (Bottom) 0.010-0.020
Oil (Steel Rail) 0.015-0.055
Oil Ring Snug Fit
Service Limit 0.006 Max.
Ring Gap
Compression (Top) 0.010-0.020
Compression (Bottom) 0.010-0.020
Oil (Steel Rail) 0.015-0.055
LUBRICATION SYSTEM
OIL PUMP
Relief Valve Spring Tension (Lbs. Spec. Length) 18.76-20.71 @ 1.172"
Drive Shaft-to-Housing Bearing Clearance 0.0015-0.0030
Relief Valve-to-Bore Clearance 0.0015-0.0030
Rotor Assembly End Clearance (Assembled) 0.004 Max.
Outer Race-to-Housing Clearance 0.001-0.013
Oil Capacity (Quarts U.S.) 5.0
Note: Dimensions in inches unless specified otherwise.
(1) Newly Installed--Refers to the condition of the "NEW" drive belt before the engine has made no more then
one rotation and before the belt has had a chance to strech or seal into the pulley grooves.
(2) Time required for plunger to leak down 1/8" of travel with 50 lb. load leakdown fluid in lash adjuster
(3) Distance in inches that front bearing is installed below front face of bearing tower.
(4) 0.002 undersize = Add 0.001 to Standard Thickness
(5) Pin bore and crank bearing bore must be parrallel and in the same vertical plane, within the specified total
difference when measured at the ends of an 8" bar -- 4" on each side of the rod centerline.
(6) When replacing pistons, measure the cylinder bore as described in the General Engine Section 21-01 and
install the specified service piston as matched to the piston bore diameter above.
