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Engine Specifications: 2002

GENERAL SPECIFICATIONS

Application Specification
Displacement 1.9L (116 Cu. In)
Bore 3.2" (82 mm)
Stroke 3.5" (90 mm)
Compression Ratio
DOHC 9.5:1
SOHC 9.3:1
Fuel System MFI
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application In. (mm)
Crankshaft
End Play
Standard .002-.008 (.05-.20)
Maximum .010 (.25)
Runout .002 (.05)
Main Bearings
Journal Diameter
Standard 2.2438-2.2444 (56.993-57.007)
Minimum 2.2437 (56.990)
Journal Out-Of-Round .0004 (.010)
Journal Taper .0004 (.010)
Oil Clearance
Standard .0002-.0020 (.006-.050)
Maximum .0022 (.055)
Connecting Rod Bearings
Journal Diameter 1.8500-1.8508 (46.990-47.010)
Journal Out-Of-Round .0004 (.010)
Journal Taper .0004 (.010)
Oil Clearance
Standard .0001-.0021 (.003-.053)
Maximum .0022 (.055)
CONNECTING RODS

Application In. (mm)
Pin Bore Diameter (Bushing)
Standard .7679-.7683 (19.505-19.517)
Maximum .7685 (19.520)
Crankpin Bore Diameter 1.9761-1.9767 (50.193-50.207)
Maximum Bend (1) .0126 (.320)
Maximum Twist (1) .0063 (.160)
Side Clearance
Standard .0065-.0171 (.165-.435)
Maximum .0185 (.470)
(1) Per 4" of rod length.
PISTONS, PINS & RINGS

Application In. (mm)
Pistons
Diameter (1) 3.2270-3.2280 (81.966-81.992)
Oil Clearance
Cylinders No. 2 & 3
Standard .0000-.0017 (.000-.044)
Maximum .0028 (.070)
Cylinders No. 1 & 4
Standard .0003-.0021 (.008-.054)
Maximum .0028 (.070)
Pin Bore Diameter .7678-.7680 (19.502-19.507)
Pins
Diameter .7676-.7677 (19.496-19.500)
Oil Clearance
Pin-To-Piston .0001-.0004 (.002-.011)
Pin-To-Rod .002-.008 (.006-.021)
Rings
No. 1
End Gap
Standard .0071-.0130 (.180-.330)
Maximum .0177 (.450)
Side Clearance .0016-.0028 (.040-.070)
No. 2
End Gap
Standard .0138-.0216 (.350-.550)
Maximum .0256 (.650)
Side Clearance .0012-.0031 (.030-.080)
No. 3 (Oil)
End Gap
Standard .0039-.0197 (0.100-.500)
Maximum .0256 (.650)
(1) Measured at right angle to piston pin hole, .20" (5 mm) from bottom of piston.
CYLINDER BLOCK

Application In. (mm)
Cylinder Bore
Diameter
Cylinders No. 2 & 3
Standard 3.2280-3.2287 (81.990-82.010)
Maximum Wear 3.2297 (82.035)
Cylinder No. 1 & 4
Standard 3.2283-3.2291 (82.000-82.020)
Maximum Wear 3.2301 (82.045)
Maximum Taper .0020 (.050)
Maximum Out-Of-Round .0020 (.050)
Cylinder Liner Protrusion
Standard Flush With Deck
Maximum (1) .0005 (.013)
Piston Protrusion
Above Deck Surface
Standard .0118 (.300)
Maximum .0149 (.379)
Below Deck Surface
Standard .0026 (.066)
Maximum .0057 (.145)
Minimum Deck Height (2) 7.4512 (189.26)
Maximum Deck Warpage
Longitudinal (Lengthwise)
Standard .0031 (.080)
Maximum .0040 (.100)
Transverse (Across)
Standard .0009 (.024)
Maximum .0020 (.050)
(1) Above or below deck surface.
(2) Distance between top of main bearing bore and deck surface.
VALVES & VALVE SPRINGS (DOHC)

Application Specification
Valve Face Angle 45-45.5°
Valve Head Minimum Margin .030" (.75 mm)
Valve Installed Height
Standard 1.548-1.567" (39.31-39.98 mm)
Minimum 1.548" (39.31 mm)
Maximum 1.586" (40.28 mm)
Valve Length
Intake
Standard 3.793-3.817 (96.28-96.74 mm)
Minimum 3.787" (96.20 mm)
Maximum 3.812" (96.74 mm)
Exhaust
Standard 3.766-3.784" (95.58-96.04 mm)
Minimum 3.760" (95.50 mm)
Maximum 3.784" (96.04 mm)
Valve Stem Diameter
Intake
Standard .2347-.2363" (5.958-5.977 mm)
Minimum .2342" (5.945 mm)
Exhaust
Standard .2342-2349" (5.944-5.963 mm)
Minimum .2336" (5.930 mm)
Valve Springs
Free Length 1.56" (40.1 mm)
Out-Of-Square
Standard .08" (2.0 mm)
Maximum .10" (2.5 mm)
Lbs. @ In. (kg @ mm) 
Pressure (Minimum)
Valve Closed 40 @ 1.22 (18 @ 31.0)
Valve Open 94 @ .85 (42 @ 21.5)
VALVES & VALVE SPRINGS (SOHC)

Application Specification
Valve Face Angle 45.0-45.5°
Valve Length
Intake
Standard 5.4539-5.4744" (138.53-139.05 mm)
Minimum 5.4520" (138.48 mm)
Maximum 5.4764" (139.10 mm)
Exhaust
Standard 5.4618-5.4823" (138.73-139.25 mm)
Minimum 5.4598" (138.68 mm)
Maximum 5.4843" (139.30 mm)
Valve Stem Diameter
Intake
Standard .2736-.2741" (6.949-6.962 mm)
Minimum .2730" (6.935 mm)
Exhaust
Standard .2726-.2736" (6.931-6.950 mm)
Minimum .2722" (6.919 mm)
Valve Head Margin
Intake
Standard .038-.050" (0.96-1.11 mm)
Minimum .035" (0.90 mm)
Exhaust
Standard .044-.056" (1.12-1.27 mm)
Minimum .039" (1.00 mm)
Valve Installed Height
Standard 1.900-1.919" (48.25-48.75 mm)
Maximum 1.921" (48.80 mm)
Valve Springs
Free Length 1.89-1.91" (48.0-48.6 mm)
Out-Of-Square
Standard .08" (2.0 mm)
Maximum .10" (2.5 mm)
Lbs. @ In. (kg @ mm) 
Pressure (Minimum)
Valve Closed 75 @ 1.61 (33 @ 41.0)
Valve Open 196 @ 1.28 (87 @ 30.0)
CYLINDER HEAD (DOHC)

Application Specification
Maximum Warpage
Head Gasket Surface
Longitudinal (Lengthwise) .0028" (.07 mm)
Transverse (Across) .0012" (.03 mm)
Manifold Surfaces .004" (.10 mm)
Valve Seat Angle 44.5-45.0°
Valve Seat Width
Intake
Standard .031-.048" (.79-1.23 mm)
Maximum .065" (1.66 mm)
Exhaust
Standard .041-.058 (1.05-1.49 mm)
Maximum .076" (1.92 mm)
Valve Seat Bore Diameter
Intake 1.315-1.316" (33.40-33.42 mm)
Exhaust 1.118-1.119" (28.40-28.42 mm)
Valve Seat Insert Diameter
Intake 1.319" (33.50 mm)
Exhaust 1.122" (28.50 mm)
Valve Guides
Cylinder Head Bore Diameter
Standard .4463-.4474" (11.337-11.363 mm)
Maximum .4476" (11.368 mm)
Guide Inside Diameter
Standard .2364-.2372 (6.000-6.020)
Maximum .239 (6.06)
Guide Installed Height .327-.357" (8.30-8.55 mm)
Valve Stem-To-Guide Oil Clearance
Intake
Standard .0010-.0025" (.023-.064 mm)
Maximum .0045" (.113 mm)
Exhaust
Standard .0015-.0030" (.037-.076 mm)
Maximum .0052" (.131 mm)
CYLINDER HEAD (SOHC)

Application Specification
Maximum Warpage
Head Gasket Surface
Longitudinal (Lengthwise) .0028" (.07 mm)
Transverse (Across) .0012" (.03 mm)
Manifold Surfaces .004" (.10 mm)
Valve Seat Angle 44.5-45.5°
Valve Seat Width
Intake
Standard .039-.051" (1.00-1.30 mm)
Maximum .063" (1.60 mm)
Exhaust
Standard .051-.063" (1.30-1.60 mm)
Maximum .075" (1.90 mm)
Valve Seat Bore Diameter
Intake 1.6333-1.6344" (41.487-41.513 mm)
Exhaust 1.377-1.3785" (34.987-35.013 mm)
Valve Seat Insert Diameter
Intake 1.6367-1.6378" (41.573-41.599 mm)
Exhaust 1.3808-1.3819" (35.073-35.099 mm)
Valve Guides
Cylinder Head Bore Diameter
Factory Size Guide
Standard .4463-.4474" (11.337-11.363 mm)
Maximum .4476" (11.368 mm)
Oversize Guide .4562-.4572" (11.587-11.613 mm)
Guide Inside Diameter
Standard .2751-.2761" (6.987-7.013 mm)
Maximum .2776" (7.050 mm)
Guide Installed Height .404-.413" (10.25-10.50 mm)
Valve Stem-To-Guide Oil Clearance
Intake
Standard .0010-.0025" (.025-.064 mm)
Maximum .0045" (.115 mm)
Exhaust
Standard .0015-.0032" (.037-.082 mm)
Maximum .0053" (.135 mm)
CAMSHAFT & CAMSHAFT DRIVE (DOHC)

Application In. (mm)
Bore Diameter
Standard 1.0638-1.0648 (27.000-27.026)
Maximum 1.0658 (27.050)
Bore Warpage (1)
Standard .0020 (.050)
Maximum .0025 (.064)
End Play
Standard .0002-.0156 (.006-.396
Maximum .018 (.45)
Camshaft Runout
Standard .003 (.080
Maximum .0047 (.120)
Journal Diameter
Standard 1.0618-1.0626 (268.950-26.970)
Minimum 1.0608 (26.925)
Lobe Lift
Intake
Standard .2042-.2074 (5.183-5.263)
Minimum .2020 (5.133)
Exhaust
Standard .2042-.2074 (5.183-5.263)
Minimum .2020 (5.133)
Oil Clearance
Standard .0021-.0030 (.030-.076)
Maximum .0049 (.125)
Timing Chain
Maximum Inner Diameter (2)
Chain Tensioner Plunger Travel (3)
Standard .045-.388 (1.16-9.85)
Maximum .709 (18.00)
(1) To measure bore warpage, place straightedge in bearing saddle. Slide a feeler gauge between straightedge and each bearing.
(2) Information is not available from manufacturer.
(3) With timing chain and guides installed.
CAMSHAFT & CAMSHAFT DRIVE (SOHC)

Application In. (mm)
Bore Diameter
Standard 1.7510-1.7520 (44.475-44.500)
Maximum 1.7525 (44.513)
Bore Warpage (1)
Standard .0020 (.050)
Maximum .0025 (.064)
End Play
Standard .003-.008 (.07-.20)
Maximum .010 (.25)
Camshaft Runout
Standard .002 (.05)
Maximum .003 (.07)
Journal Diameter
Standard 1.7480-1.7490 (44.399-44.424)
Minimum 1.7470 (44.375)
Lobe Lift
Standard .2531-.2556 (6.428-6.493)
Minimum .2520 (6.400)
Journal Oil Clearance
Standard .0020-.0040 (.051-.101)
Maximum .0054 (.138)
Timing Chain
Inner Diameter (2)
Standard 16.50-16.61 (419.0-422.0)
Maximum 16.73 (425.0)
Chain Tensioner Plunger Travel (3)
Standard .045-.388 (1.16-9.85)
Maximum .7092 (18.0)
(1) To measure bore warpage, insert a straightedge into camshaft bearing bores. Slide a feeler gauge between straightedge and bearing at each end of head.
(2) Information unavailable from manufacturer.
(3) With timing chain and guides installed.
VALVE LASH ADJUSTERS (DOHC)

Application In. (mm)
Bore Diameter
Standard .4727-.4736 (12.008-12.030)
Maximum .4744 (12.040)
Lash Adjuster Body Diameter
Standard .4719-.4724 (11.986-12.000)
Minimum .4716 (11.980)
Oil Clearance
Standard .003-.0017 (.008-.044)
Maximum .0024 (.060)
VALVE LIFTERS (SOHC)

Application In. (mm)
Bore Diameter
Standard .8434-.8444 (21.422-21.448)
Maximum .8445 (21.450)
Lifter Diameter
Standard .8420-.8427 (21.387-21.405)
Minimum .8417 (21.380)
Oil Clearance
Standard .0007-.0024 (.017-.061)
Maximum .0028 (.070)
Lifter Length
Standard 2.0563-2.0697 (52.230-52.570)
Minimum 2.0531 (52.150)
Lifter Width (At Flats)
Standard .7551-.7598 (19.180-19.300)
Minimum .7539 (19.150)
Lifter Guide Plate Width
Standard .7634-.7685 (19.390-19.520)
Maximum .7632 (19.385)
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