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303-01A Engine - 2.0L > < Bearing Inspection

Cougar 1999 (08.1998-01.2001)

Engine System - General Information - Specifications Cougar 1999 (08/1998-01/2001)

General Specifications 2.0L

Item Specification
Displacement in liters 2.0
Number of cylinders 4
Bore and stroke mm 84.8 x 88
Firing order 1-3-4-2
Oil pressure (hot 2000 RPM) kPa (psi) 240-450 (35-65)
Drive belt tension in Newton 178-311
Compression ratio 9.2:1 ± 0.25
Coolant capacity in liters 5.0-5.8

Cylinder head and valve train 2.0L

Item Specification
Valve guide inner diameter (I.D.) mm 8.063-8.094
Intake and exhaust mm 8.063-8.094
Valve seats width-intake and exhaust mm 1.75-2.32
Angle degrees runout(total indicated runout [TIR]) mm 45 0.064 MAX.
Bore diameter (insert counterbore diameter) intake mm 39.940 MIN. 39.965 MAX.
Bore diameter (insert counterbore diameter) exhaust mm 34.940 MIN. 34.965 MAX.
Gasket surface flatness mm 0.04/26 0.08/156 0.15 Total
Head face surface finish mm 0.2/2.5 0.8
Valve stem to guide clearance intake mm 0.020-0.069
Valve stem to guide clearance exhaust mm 0.046-0.095
Valve head diameter intake mm 38.9-39.1
Valve head diameter exhaust mm 33.91-34.11
Valve face runout limit intake and exhaust mm 0.05
Valve face angle degree 45.6
Valve stem diameter standard (STD) intake mm 8.025-8.043
Valve stem diameter standard (STD) exhaust mm 7.996-8.017
Valve springs compression pressure (N @ mm) loaded 892.7 @ 27.71
Valve springs compression pressure (N @ mm) unloaded 422 @ 37.1
Valve springs assembled height mm service limit, pressure lost @ specified height % 36.9-37.5 5
Valve springs free length 47.2
Valve springs installed spring height mm 35.99-39.19

Rocker arm 2.0L

Item Specification
Ratio 1.65
Valve tappet, hydraulic diameter (STD) mm 22.200-22.212
Valve tappet, hydraulic diameter clearance to bore mm 0.023-0.065
Valve tappet roundness mm 0.013
Finish micro mm 0.2
Valve tappet service limit mm 0.127
Collapsed tappet gap mm 0-4.5
Tappet bore diameter mm 22.25 ± .015
Camshaft bore inside diameter mm No. 1, 2, 3, 4 and 5 mm 45.796-45.821

Camshaft 2.0L

Item Specification
Lobe lift intake mm 6.23
Lobe lift exhaust mm 6.23
Allowable lobe lift loss mm 0.127
Theoretical valve maximum lift intake mm 10.28
Theoretical valve maximum lift exhaust mm 10.28
End play mm 0.02-0.20
Service limit mm 0.20
Journal to cylinder head bearing surface clearance mm 0.0335-0.0835
Journal diameter standard mm runout limit 0.127 (Runout of center bearing relative to bearing Nos. 1 and 5)
Journal diameter standard mm out-of-round 0.08
Camshaft drive assembled gear face runout crankshaft mm 0.65
Camshaft drive assembled gear face runout camshaft mm 0.275

Cylinder block 2.0L

Item Specification
Head gasket surface overall flatness mm 0.076
Head gasket surface finish roughness height (CLA) mm 3.8-2.0
Head gasket surface finish roughness height cutoff mm 0.8
Dowel height chamfer mm total mm 0.8x30 degrees 12.5
Cylinder bore diameter mm 84.8
Piston to cylinder bore clearance mm 0.020 -0.040
Surface finish (RA) each bore min. 15-38
Average of all bores of a cylinder block (RA) min. 20-30
Out of round limit mm 0.025
Taper limit mm 0.013
Main bearing bore diameter @ ± 30 degrees PF bearing cap P/L mm 62.2835-62.3145
Other than above mm 62.2935±.0100

Crankshaft 2.0L

Item Specification
Main bearing journal diameter mm 57.98-58.0
Out of round limit mm 0.008
Taper limit mm 0.008 per 25.4
Journal runout limit mm 0.05
Runout of bearings 2, 3, and 4 crankshaft end play mm 0.100-0.300
Surface finish (RMS) micro mm 0.3
Clearance to crankshaft mm 0.020-0.065
Thrust bearing journal length mm 28.825-28.854
Connecting rod journal diameter mm 43.89-43.91
Out of round limit 0.008
Taperl limit mm 0.008 per 25.4
Surface limit (RMS) micro mm 0.6 Rear 0.9 Front
Main bearing thrust face surface finish (RMS) micro mm 0.6
Rear micro mm 0.9
Front runout limit (T.I.R.) mm 0.025
Flywheel clutch face runout limit (T.I.R.) mm 0.180
Flywheel ring gear lateral runout (T.I.R.) manual transmission mm 0.64
Flywheel ring gear lateral runout (T.I.R.) automatic transmission mm 1.5
Crankshaft end play mm 0.100-0.300

Connecting rod 2.0L

Item Specification
Connecting rod bearings clearance to crankshaft mm 0.020-0.065
Bearing wall thickness (STD) mm 1.476-1.488
Clearance of crankshaft W/O cylinder head mm Desired 0.0457-0.0660 Allowable 0.0461-0.0859
Clearance of crankshaft W/cylinder head mm Desired 0.0279-0.0483 Allowable 0.0276-0.0674
Bearing wall thickness mm 2.117-2.129
Connecting rod piston pin bore diameter mm 20.570-20.610
Crankshaft bearing bore diameter mm 46.89-46.91
Out-of-round limit piston pin bore mm 0.008
Taper limit piston pin bore mm/mm 0.0038/25.4
Length (center to center ) mm 131.905-131.975
Out-of-round limit - bearing bore mm 0.010
Taper limit - bearing bore mm 0.010
Alignment bore to bore (max. differential) twist mm (bend mm) 0.05 (0.038)
Side clearance (assembled to crank) std. mm (service limit mm) 0.092-0.268 (0.356)

Pistons 2.0L

Item Specification
Piston to bore clearance rebuild mm 0.020-0.040
Piston to bore clearance service mm 0.020-0.070
Piston diameter mm 84.77-84.80
Pin bore diameter mm 20.632-20.641
Ring groove width compression (top) mm 1.53 -1.55
Ring groove width (bottom) mm 1.53-1.55
Oil ring groove width mm 4.008-4.032
Compression ring (top) to ring groove clearance mm 0.04-0.08
Compression ring (bottom) to ring groove clearance mm 0.06-0.09
Squish height mm 0.908-1.858
Piston pin length mm 66.2-67.0
Piston pin diameter standard mm 20.622-20.631
Piston to pin clearance mm 0.0007-0.013
Pin to rod clearance kilo-Newton Press-fit-8
Piston rings ring width compression top mm 1.47-1.49
Compression (bottom) mm 1.46-1.49
Oil ring service limit mm Side seal (snug fit) (side clearance) 0.15
Ring gap compression (top) mm 0.25-0.28
Ring gap compression (bottom) mm 0.25-0.28
Ring gap oil ring (steel rail) mm 0.04-1.68
Side clearance 1st ring mm 0.04-0.08
Side clearance 2nd ring mm 0.04-0.09

Lubrication system 2.0L

Item Specification
Oil pump relief valve spring tension N @ mm 41.4-45.8 @ 28.1
Relief valve to bore clearance mm 0.02-0.08
Oil pump type Gerotor
Rotor clearance outer gear to housing clearance mm 0.074-0.161
Inner and outer gear to cover clearance (end play) mm 0.013-0.089
Inner to outer gear tip clearance mm 0.05-0.18
Oil capacity with filter in liters 3.76 (4)

Engine general specifications 2.5L

Item Specification
Displacement 2.5L (153 CID)
Number of cylinders 6
Bore and stroke 82.4 x 79.5
Firing order 1-4-2-5-3-6
Oil pressure (hot 1500 RPM) 138-310 kPa (20-45 psi)

Cylinder head and valve train 2.5L

Item Specification
Combustion chamber volume 44.5 ±1.5 cc
Valve seats - width intake 1.1-1.4 mm
Width exhaust 1.4-1.7 mm
Angle 44.75 degrees
Runout (T.I.R.) max 0.04 mm
Valve stem to guide clearance intake 0.020-0.069 mm
Valve stem to guide clearance exhaust 0.045-0.094 mm
Valve head diameter intake 32 mm
Valve head diameter exhaust 26 mm
Gauge diameters 31 and 24.5 mm
Valve face runout limit 0.05 mm
Valve face angle 45.5 degrees
Valve stem diameter (STD) intake 5.975-5.995 mm
Valve stem diameter (STD) exhaust 5.950-5.970 mm
Valve springs compression pressure (N @ spec length) intake 680 N @ 30.19mm
Valve springs compression pressure (N @ spec length) exhaust 680 N @ 30.19mm
Free length (approximate) intake 46.8mm
Free length (approximate) exhaust 46.8mm
Installed pressure (N @ spec length) intake 228 N @ 39.99 mm
Installed pressure (N @ spec length) exhaust 228 N @ 39.99 mm
Service limit 10% Pressure Loss @ 30.09
Out of square limit 1%
Rocker arm ratio 1.8:1
Hydraulic valve tappet diameter (STD) 16-15.988 mm
Clearance to bore 0.018-0.069 mm
Service limit 0.016 mm
Hydraulic leakdown rate 5-25 seconds
Collapsed valve tappet gap - desired 0.50-1.11 mm

Camshaft 2.5L

Item Specification
Lobe lift
Intake (primary) 4.79 mm
Intake (secondary) 4.79 mm
Exhaust 4.79 mm
Allowable lobe lift loss 0 mm
Theoretical valve lift @ zero lash
Intake (primary) 9.80 mm
Intake (secondary) 9.80 mm
Exhaust 9.80 mm
End play
Standard 0.025-0.165 mm
Service limit 0.190 mm
Journal to bearing clearance
Standard 0.025-0.076 mm
Service limit 0.121 mm
Journal diameter (all) 26.926-26.936 mm
Bearing inside diameter (all) 27.012-26.897 mm

Cylinder block 2.5L

Item Specification
Head gasket surface
Head gasket surface flatness - cylinder block: 0.025 / 25 x 25.050/ 150 x 150
Head gasket surface flatness-cylinder head: 0.025 / 25 x 25.050/ 150 x 150
Head gasket surface flatness-cylinder block: 0.025 / 25 x 25.050/ 150 x 150
Head gasket surface finish
Head gasket surface flatness-cylinder head: 0.025 / 25 x 25.050/ 150 x 150
Main bearing bore diameter 68.998-69.022 mm
Cylinder bore
Diameter Grade 1: 82.4-82.410 mm grade 2: 82.411-82.421 mm grade 3: 82.420-82.430 mm
Surface finish (RMS) 0.2-0.6 microns
Out-of-round limit 0.015 mm
Out-of-round service limit 0.020 mm
Taper service limit 0.006 mm

Crankshaft 2.5L

Item Specification
Main bearing journal diameter 62.968-62.992 mm
Connecting rod journal diameter 49.970-49.990 mm
Crankshaft free play 0.110-0.232 mm
Crankshaft runout to rear face of cylinder block 0.050 mm max
Connecting rod bearings
Clearance to crankshaft 0.028-0.066 mm
Bearing wall thickness (STD) 0.250 mm undersize - add 0.125 mm to standard or grade 2 thickness 1.503
Main bearings
Clearance to crankshaft-desired 0.025-0.045 mm
Clearance to crankshaft-allowable 0.025-0.050 mm
Bearing shells
Grade 1 Standard
Grade 2 + 0.004 mm
Grade 3 + 0.008 mm

Connecting rod 2.5L

Item Specification
Piston pin bore diameter 21.071-21.032 mm
Length (center to center) 138.06-138.4 mm
Alignment (bore to bore max difference) Pin bore and crankshaft bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of the centerline
Twist 0.050 mm per 25
Band 0.038 mm per 25
Side clearance (assembled to crank)
Standard 0.100-0.30 mm
Service limit 0.35 mm max.

Pistons 2.5L

Item Specification
Diameter Measured at 43 mm from outer perimeter top of piston to the pin axis.
Coded grade 1 82.390-82.410 mm
Coded grade 2 82.398-82.442 mm
Coded grade 3 82.410-82.430 mm
Piston to bore clearance 0.012 to 0.022 mm
Pin bore diameter 21.008-21.012 mm
Ring groove width
Compression (top)
Compression (bottom)
Oil ring 3.030-3.055 mm
Piston pin
Lenght 55.05-55.47 mm
Diameter 21.011-21.013 mm
Pin to piston clearance -0.005 to +0.001 mm
Pin to rod clearance
Standard 0.004-0.020 mm
Service limit 0.035 mm
Side clearance
Compression (top) 0.040-0.075 mm
Compression (bottom) 0.040-0.085 mm
Oil ring Snug fit
Service limit 0.10 mm
Piston ring gap Specification 82.4 mm diameter guage
Compression (top) - gauge diameter 0.100-0.250 mm
Compression (bottom) - gauge diameter 0.27-0.42 mm
Oil Ring (steel rail) - gauge diameter 0.15-0.65 mm
Compression (top) service limit 0.50 mm max
Compression (bottom) - service limit 0.65 mm max
Oil ring (steel rail) - service limit 0.90 mm max

Lubrication system 2.5L

Item Specification
Oil capacity with filter change 5.5 liter

Drive belt tension 2.5L

Item Specification
Note: Belts have differing tension specifications depending on whether they are new installed or used Automatic tensioners
6 Rib front end accessory drive (FEAD)-Water pump belt Automatic tensioners
3 Rib rear end accessory drive (READ)-Water pump belt No adjustment required

303-01A Engine - 2.0L > < Bearing Inspection