The Merkur Encyclopedia

2.3 L Turbo Engine Specifications

GENERAL SPECIFICATIONS (from the XR Manual)


 

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 Train Specifications



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 ARRANGEMENT (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


    Intake 0.3566-0.3573
    Exhaust 0.3461-0.3568


    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


    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)


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


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

    Length (Center-to-Center) 5.2031-5.2063
    Alignment (Bore-to-Bore Max. Difference) (5)

    Side Clearance (Assembled to Crank)

 

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

  1. Ring Width

    Side Clearance

    Ring Gap

    Ring Gap

 

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 than one rotation and before the belt has had a chance to stretch 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 parallel 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.