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Section 2 (Engine Mechanical - 2.0L GTDI): Specifications

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MATERIAL SPECIFICATIONS

Item Specification Fill Capacity
Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil (Canada)
XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or equivalent
WSS-M2C946-A, 5W30; 5.4 L (5.7 qt)
GENERAL SPECIFICATIONS

Item Specification
Engine 
Displacement 2.0L (122 CID)
No. of cylinders 4
Bore/stroke 87.5 mm (3.4449 in) - 83.1 mm (3.2717 in)
Firing order 1-3-4-2
Oil pressure (hot @ 2, 000 rpm) 200 kPa (29.01 psi) - 268 kPa (38.87 psi)
Compression ratio 9.3:1
Spark plug NGK T4025R
Spark plug gap .8 mm (0.031 in)
Engine weight (without accessory drive components and flexplate or flywheel) 141 kg (311 lb)
Cylinder Block 
Cylinder bore diameter 87.5-87.53 mm (3.4449-3.4461 in)
Cylinder bore maximum out-of-round 0.008 mm (0.0003 in)
Main bearing bore diameter 57.018-57.040 mm (2.245-2.246 in)
Head gasket surface flatness 0.1 mm (0.0039 in) - 0.05 mm (0.002 in)/200 mm (7.874 in) x 200 mm (7.874 in)
Piston 
Piston diameter (grade 1) 87.465 mm (3.4435 in) - 87.475 mm (3.4439 in)
Piston diameter (grade 2) 87.4725 mm (3.4438 in) - 87.4875 mm (3.4444 in)
Piston diameter (grade 3) 87.485 mm (3.4443 in) - 87.495 mm (3.4447 in)
Piston-to-cylinder bore clearance 0.0225 mm (0.0009 in) - 0.0475 mm (0.0019 in)
Piston ring groove width - compression (top) 1.23 mm (0.0484 in) - 1.25 mm (0.0492 in)
Piston ring groove width - compression (bottom) 1.23 mm (0.0484 in) - 1.25 mm (0.0492 in)
Piston ring groove width - oil ring 2.03 mm (0.0799 in) - 2.05 mm (0.0807 in)
Piston skirt coating thickness 0.009 mm (0.0004 in) - 0.019 mm (0.0007 in)
Piston Pin 
Diameter 22.497 mm (0.8857 in) - 22.5 mm (0.8858 in)
Length 55.7 mm (2.1929 in) - 56.0 mm (2.2047 in)
Piston-to-pin clearance 0.0035 mm (0.0001 in) - 0.0115 mm (0.0005 in)
Piston pin-to-connecting rod clearance 0.010 mm (0.0004 in) - 0.019 mm (0.0007 in)
Piston ring width - compression (top) 1.2 mm (0.05 in)
Piston ring width - compression (bottom) 1.2 mm (0.05 in)
Piston ring width - oil 2 mm (0.08 in)
Piston ring gap (in bore) - compression (top) 0.17 mm (0.0067 in) - 0.27 mm (0.0106 in)
Piston ring gap (in bore) - compression (bottom) .45 mm (0.0177 in) -.65 mm (0.0256 in)
Piston ring gap (in bore) - oil 0.15 mm (0.0059 in) - 0.45 mm (0.0177 in)
Connecting rod bearing-to crankshaft clearance 0.027 mm (0.0011 in) - 0.052 mm (0.002 in)
Connecting rod bearing thickness 1.495 mm (0.0589 in) - 1.519 mm (0.0598 in)
Connecting rod crankshaft bore diameter 55.025 mm (2.1663 in) - 55.045 mm (2.1671 in)
Connecting rod pin bore diameter 22.510 mm (0.8862 in) - 22.516 mm (0.8865 in)
Connecting rod length (center-to-center) 155.869 mm (6.1366 in)
Connecting rod side clearance (assembled to crank) 2.59 mm (0.1020 in) - 3.69 mm (0.1453 in)
Axial clearance 0.14 mm (0.0055 in) - 0.36 mm (0.0142 in)
Crankshaft 
Main bearing journal diameter 51.978 mm (2.0464 in) - 52.002 mm (2.0473 in)
Main bearing clearance 0.016 mm (0.0006 in) - 0.046 mm (0.0018 in)
Connecting rod journal diameter 51.978 mm (2.0464 in) - 52.002 mm (2.0473 in)
End play 0.22 mm (0.0087 in) - 0.45 mm (0.0177 in)
Cylinder Head 
Cylinder head flatness 0.08 mm (0.0031 in) maxim overall, a maximum of 0.05 mm (0.0020 in) within 150 mm (5.9055 in) and a maximum of 0.025 mm (0.0010 in) within 25 mm (0.9843 in)
Maximum valve lift @ 0 lash - exhaust 7.4 mm (0.291 in)
Maximum valve lift @ 0 lash - intake 8.3 mm (0.326 in)
Valve guide diameter 5.509 mm (0.2169 in) - 5.539 mm (0.2181 in)
Valve seat width - intake/exhaust 1.40 mm (0.0551 in) - 1.50 mm (0.0591 in)
Valve seat angle 45
Valve seat runout 0.075 mm (0.003 in)
Valve lash adjuster bore diameter 31 mm (1.2205 in) - 31.03 mm (1.2217 in)
Cam bore diameter 25.015 mm (0.9848 in) - 25.04 mm (0.9858 in)
Valve 
Valve head diameter - intake 32.5 mm (1.2795 in)
Valve head diameter - exhaust 28 mm (1.1024 in)
Valve stem diameter - intake 5.5 mm (0.2165 in)
Valve stem diameter - exhaust 5.5 mm (0.2165 in)
Valve stem-to-guide clearance - intake 0.03 mm (0.0012 in) - 0.07 mm (0.0028 in)
Valve stem-to-guide clearance - exhaust 0.03 mm (0.0012 in) - 0.07 mm (0.0028 in)
Valve face runout 0.05 mm (0.002 in)
Valve face angle 45.25 - 45.75
Valve Spring - Compression Pressure 
Intake and exhaust (installed) 17 kg (37.478 lb)
Intake (valve open) 9.2 mm (0.3622 in) of lift 39 kg (85.979 lb)
Exhaust (valve open) 7.4 mm (0.29 in) of lift 42 kg (93.338 lb)
Free length 47.904 mm (1.8862 in)
Assembled height 37.9 mm (1.4921 in)
Valve Tappet 
Diameter 30.98 mm (1.2197 in) - 30.964 mm (1.2191 in)
Tappet-to-valve clearance - intake 0.19 mm (0.0075 in) - 0.31 mm (0.0122 in)
Tappet-to-valve clearance - exhaust 0.30 mm (0.0118 in) - 0.42 mm (0.0165 in)
Tappet-to-bore clearance 0.02 mm (0.0008 in) - 0.06 mm (0.0024 in)
Camshaft 
Lobe lift - intake 8.3 mm (0.326 in)
Lobe lift - exhaust 7.4 mm (0.291 in)
Runout 0.03 mm (0.0012 in)
Thrust clearance 0.115 mm (0.0045 in) - 0.145 mm (0.0057 in)
Journal diameter 24.96 mm (0.9827 in) - 24.98 mm (0.9835 in)
Journal-to-bore clearance 0.035 mm (0.0014 in) - 0.08 mm (0.0031 in)
TORQUE SPECIFICATIONS

Description Nm lb-ft lb-in
A/C compressor bolt 25 18 -
A/C compressor nut 25 18 -
A/C compressor stud 9 - 80
A/C compressor tube bracket bolt 25 18 -
Accessory drive belt tensioner bolts 25 18 -
Balancer unit bolts (1) - - -
Battery terminal nut 9 - 80
Bellhousing-to-engine bolts 48 35 -
Bellhousing-to-engine stud bolt 48 35 -
Bellhousing-to-oil pan bolts 48 35 -
Brake vacuum pump adapter 63 46 -
Brake vacuum pump bolts 10 - 89
Camshaft bearing cap bolts(1) - - -
Camshaft phaser and sprocket bolts 72 53 -
CAC inlet tube clamp 5 - 44
CAC intermediate tube mounting bracket fasteners 8 - 71
CAC outlet tube clamp 5 - 44
Connecting rod cap bolts(1) - - -
Coolant outlet bolts 10 - 89
Coolant pump bolts 10 - 89
Coolant pump pulley bolts 20 - 177
CKP sensor bolts 7 - 62
Crankshaft pulley bolt(1) - - -
Crankshaft rear seal with retainer plate bolts(1) - - -
Crankcase vent oil separator bolts 10 - 89
Cylinder head bolts(1) - - -
CHT sensor 11 - 97
Engine appearance cover mounting stud 5 - 44
Engine front cover bolts(1) - - -
Engine eye lift bolts 47 35 -
Engine mount bolts 90 66 -
Engine mount nuts 90 66 -
EOP switch 15 - 133
Engine plug bolt 20 - 177
Flexplate bolts(1) - - -
Fuel injection pump bracket bolts 17 - 150
Fuel injection pump housing stud bolts (2) - - -
Fuel jumper tube bolt 8 - 71
Fuel rail bolts(1) - - -
Generator bolt/stud bolt 25 18 -
Generator terminal nut 17 - 150
Ground wire bolt (on cylinder head) 20 - 177
Ground wire nut (on LH inner fender) 9 - 80
Ground wire nut (on starter stud bolt) 18 - 159
Ground strap nut (on RH inner fender) 11 - 97
Ground strap nut (on engine front cover stud bolt) 9 - 80
High pressure fuel tube bracket bolts 10 - 89
High pressure fuel tube nuts(1) - - -
Ignition coil-on-plug bolts(1) - - -
Intake manifold bolts(1) - - -
KS 20 - 177
Main bearing beam bolts(1) - - -
Oil filter (3) - - -
Oil filter adapter bolts 25 18 -
Oil pan drain plug 27 20 -
Oil pan bolts(1) - - -
Oil pan-to-bellhousing bolts 48 35 -
Oil pump drive chain tensioner shoulder bolt 10 - 89
Oil pump drive chain tensioner bolt 10 - 89
Oil pump bolts(1) - - -
Oil pump screen and pickup tube bolts 10 - 89
Oil pump sprocket bolt 25 18 -
Piston oil cooler bolts 10 - 89
Power steering pump 25 18 -
Power steering pump bracket bolts 25 18 -
Power steering reservoir bolts 8 - 71
Power steering tube bracket nut 9 - 80
RH halfshaft bracket nuts 25 18 -
Spark plugs 12 - 106
Starter motor stud bolt 35 26 -
Starter wire terminal nut (large) 12 - 106
Starter wire terminal nut (small) 5 - 44
Thermostat housing bolts 10 - 89
Timing chain guide bolts 10 - 89
Timing chain tensioner bolts 10 - 89
Torque converter nuts 40 30 -
TCM bracket nut 9 - 80
Transaxle selector lever cable bracket bolts 25 18 -
Transaxle support insulator bracket bolt 80 59 -
Transaxle support insulator bracket bolt 80 59 -
Transaxle support insulator bracket nut 63 46 -
Transaxle support insulator through bolt 175 129 -
Turbocharger coolant supply banjo bolts 28 - 21
Turbocharger heat shield bolts 10 - 89
Turbocharger inlet tube bolt/stud bolt 5 - 44
Turbocharger inlet/outlet tube clamps 5 - 44
Turbocharger nuts 50 37 -
Turbocharger oil return tube bolts 10 - 89
Turbocharger oil supply banjo bolts 25 18 -
Turbocharger studs 17 - 150
Valve cover retainers(1) - - -
VCT solenoid bolts 10 - 89
(1) Refer to the appropriate procedure in this service information.
(2) 15 Nm plus an additional 60 degrees
(3) 8 Nm plus an additional 180 degrees