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.