SECTION 1C1

ENGINE MECHANICAL - FAM II 2.4D

Caution : Disconnect the negative battery cable before removing
or installing any electrical unit or when a tool or equipment could
easily come in contact with exposed electrical terminals.
Disconnecting this cable will help to prevent personal injury and
damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
SPECIFICATIONS
Engine Specifications
Application Description Unit FAM II 2.4D
Engine Type - 4 Cylinder (In-Line)
Displacement cm 2,405
mm 87.5 x 100 (3.44 x
Bore Stroke
(in.) 3.94)
General Data
Compression Ratio - 9.6 : 1
Firing Order - 1-3-4-2
Maximum Power kw 100 kw @ 5,000 rpm
Maximum Torque Nm 220 Nm @ 2,200 rpm
mm 87.485~87.505
Diameter
(in.) (3.444~3.445)
mm
Out of Round (MAX) 0.013 (0.0005)
(in.)
mm
Taper (MAX) 0.013 (0.0005)
(in.)
Cylinder Bore mm
Piston Protrusion 0
(in.)
Oversize (Measure
mm Available in 0.50 mm
Replacement Piston before Re-
(in.) (0.019 in.) to suit bore
boring)
mm
Block Face Distortion 0.01 MAX (0.00039)
(in.)
mm 87.465~87.485
Diameter
(in.) (3.443~3.445)
mm 0.010~0.030
Clearance to Bore
(in.) (0.00039~0.0020)
Ring Groove mm 1.230 ~ 1.250 (0.04842
Pistion Top
Width (in.) ~ 0.04921)
mm 1.510 ~ 1.530 (0.05945
. 2nd
(in.) ~ 0.0602)
mm 2.530 ~ 2.550 (0.09961
. Oil
(in.) ~ 0.10040)
 Application Description Unit FAM II 2.4D
Ring Groove mm 79.96 ~ 80.66 (3.1480
Top
Inner Diameter (in.) ~ 3.1756)
mm 78.40 ~ 79.10 (3.0866
. 2nd
(in.) ~ 3.1142)
mm 80.06 ~ 80.76 (3.15197
. Oil
(in.) ~ 3.17953)
Top Compression Ring End mm 0.21 ~ 0.36 (0.00827 ~
Gap (in.) 0.01417)
Second Compression Ring End mm 0.36 ~ 0.61 (0.01417 ~
Gap (in.) 0.02402)
mm 0.16 ~ 0.76 (0.0063 ~
Oil Ring End Gap
(in.) 0.02992)
Piston Ring mm 1.170 ~ 1.190 (0.04606
Top
Width (in.) ~ 0.04685)
mm 1.466 ~ 1.490 (0.05772
. 2nd
(in.) ~ 0.05866)
mm
. Oil 2.5 (0.09842)
(in.)
Piston Rings
Piston Ring mm 2.86 ~ 3.15 (0.11260 ~
Top
Thickness (in.) 0.12402)
mm 3.50 ~ 3.70 (0.13780 ~
. 2nd
(in.) 0.14567)
mm 2.159 ~ 2.337 (0.085 ~
. Oil
(in.) 0.092)
Ring Groove mm 0.040 ~ 0.080 (0.00157
Top
Clearance (in.) ~ 0.00315)
mm 0.020 ~ 0.064 (0.00079
. 2nd
(in.) ~ 0.00252)
mm 0.3 ~ 0.5 (0.01181 ~
. Oil
(in.) 0.01969)
mm 20.9910~20.9970
Diameter
(in.) (0.82641~0.82665)
0.7~0.9
mm
Pin Offset (0.0275~0.0354)
(in.)
Toward Thrust Side
Piston Pin mm 0.011~0.014
Clearance : In Piston
(in.) (0.00043~0.00055)
mm
Clearance : In Rod Interference Fit in Rod
(in.)
mm
Length 61.5 (2.42)
(in.)
mm
Valve Lift Intake 9.2 (0.36)
Camshaft (in.)
. Exhaust mm 9.2 (0.36)
 Application Description Unit FAM II 2.4D
(in.)
Camshaft Cap to Bearing mm 0.04~0.144
Journal Clearance (in.) (0.0015~0.0056)
mm 42.455~43.470
Bearing Journal OD
(in.) (1.6714~1.7114)
mm 57.974 - 57.995
Main Journal Diameter (All)
(in.) (2.2824~2.2833)
Main Journal - Radial Runout
(Shaft Support on No. 1 and mm
0.03 (0.00118)
No. 5 Bearings Measured at (in.)
No. 3 Journal)
Crankshaft
mm 0.015~0.040
Main Bearing Clearance (All)
(in.) (0.00059~0.00157)
mm 0.070~0.302
End Play
(in.) (0.0027~0.0118)
Service Oversize (Available in mm 0.25 and 0.5 (0.00098
2 sizes) (in.) and 0.019)
mm 48.970~48.988
Diameter (All)
(in.) (1.9279~1.9287)
mm
Out of Round (MAX) 0.004 (0.00015)
Connecting (in.)
Rod Journal mm 0.006~0.031
Rod Bearing Play
(in.) (0.00023~0.00122)
mm 0.013~0.041
Rod Bearing Clearance
(in.) (0.0005~0.0016)
mm
Valve Stem Protrusion 39.2 MAX (1.544)
(in.)
mm
Valve Guide Height 13.7~14.0 (0.53~0.55)
(in.)
Cylinder Head
mm 133.975~134.025
Overall Height
(in.) (5.2741~5.2759)
Minimum Overall Height After mm
133.9 (5.271)
Machining (in.)
Valve Lash Compensators - Hydraulic
mm
Seat Runout (MAX, All) 0.03 (0.0018)
(in.)
mm
Face Runout (MAX, All) 0.03 (0.0018)
(in.)
Valve System mm 32 0.1 (1.2598
Valve Diameter Intake
(in.) 0.0039)
mm 29 0.1 (1.1417
. Exhaust
(in.) 0.00039)
Valve Stem mm 5.955~5.970
Intake
Diameter (in.) (0.234~0.235)
 Application Description Unit FAM II 2.4D
mm 5.945~5.960
. Exhaust
(in.) (0.2346~0.2360)
Valve Seat mm
Intake 1.0~1.5 (0.039~0.059)
Width (in.)
mm
. Exhaust 1.7~2.2 (0.066~0.086)
(in.)
mm
Valve Face Angle 44
(in.)
mm
Valve Seat Angle 45
(in.)
mm 6.000~6.012
Valve Guide Inside Diameter
(in.) (0.2362~0.2367)
Type - Rotary (Trochoild)
0.10~0.20
Gear Lash -
(0.0040~0.008)
mm 0.11~0.19
Outer Gear to Body
(in.) (0.0043~0.0074)
Oil Pump mm 0.11~0.24
Outer Gear to Crescent
(in.) (0.0043~0.009)
mm 0.18~0.26
Inner Gear to Crescent
(in.) (0.007~0.010)
mm 0.03~0.10
End Clearance
(in.) (0.001~0.004)
Rear Main Bearing Cap - Three-Bond 1217F
Camshaft Carrier-to-Cylinder HN 1581 (Loctite
-
Head 515)
HN 1256 (Loctite
Oil Pan Bolts -
542)
HN 1256 (Loctite
Oil Pump Bolts -
Sealants and 542)
Adhesives HN 1256 (Loctite
Oil Pan Pickup Tube Bolts -
542)
HN 1256 (Loctite
Oil Gallery Plug -
542)
Coolant Jacket Caps and Plugs HN 1756 (Loctite
-
(Freeze Plugs) 176)
Exhaust Manifold Studs/Nuts - Anti-seize Compound
Type - Forced Feed
Oil Pump Type - Rotary (Trochoid)
Lubricating Oil Filter Type - Cartridge
System Oil Pan Capacity (Including Oil
L 4.5L
Filter)
Oil Pan Capacity (Excluding Oil L 4.3L
 Application Description Unit FAM II 2.4D
Filter)
API SL (ILSAC GF-III)
grade SAE 5W-30
Engine Oil Type -
* Hot area : SAE 10W-
30
Fastener Tightening Specifications
Application Nm Lb-Ft Lb-In
Air Cleaner Element Cover Screws 2 - 18
Air Cleaner Housing Bolts 6 - 53
Battery Hold-Down Bar Bracket Retaining
10 - 89
Nuts
Battery Tray Retaining Bolts 10 - 89
Camshaft Bearing Cap Bolts 8 - 71
35 + 45 + 26 + 45 +
Connecting Rod Cap Bearing Bolts -
15 15
Coolant Bypass Housing Bolts 15 11 -
Crankshaft Balancer Unit Assembly Bolts 20 + 45 15 + 45 -
50 + 45 + 37 + 45 +
Crankshaft Bearing Cap Bolts -
15 15
Crankshaft Pulley Bolts 20 15 -
135 + 30 100 + 30
Crankshaft Timing Belt Drive Gear Bolt -
+ 10 + 10
25 + 90 + 18 + 90 +
Cylinder Head Bolts -
90 + 90 90 + 90
Cylinder Head Cover Bolts 8 - 71
Direct Ignition System and EGR Mounting
25 18 -
Bracket Bolts
Engine Beautification Cover Bolts and Nuts 8 - 71
Engine Beautification Cover Bracket
20 15 -
Retaining Bolt
Engine Fuse Block Lower Cover Bolts 10 - 89
Engine Fuse Block Retaining Bolts 3 - 27
Engine Mount Adapter Bolts 50 37 -
Engine Mount Adapter Support Bracket
45 33 -
Bolts
Engine Mount Frame Side Bracket Bolt 100 74 -
Engine Mount Frame Side Bracket Nuts 90 66 -
Evaporative Emission Canister Purge
5 - 44
Solenoid Brakcet Bolt
50 + 60 + 37 + 60 +
Exhaust Camshaft Gear Bolt -
15 15
Exhaust Front Pipe Mounting Bracket Bolt
40 30 -
and Nut
 Application Nm Lb-Ft Lb-In
Exhaust Manifold Heat Shield Bolts 15 11 -
Exhaust Manifold Retaining Nuts 22 16 -
Flexible Plate Bolts 65 48 -
65 + 30 + 48 + 30 +
Flywheel Bolts -
15 15
Front Timing Belt Cover Bolts 6 - 53
Fuel Rail Assembly Retaining Bolts 25 18 -
Generator-to-Generator Lower Support
40 30 -
Bracket Through Bolt & Nut
Generator-to-Intake Manifold Strap Bracket
25 18 -
Bolt at Intake Manifold
Generator-to-Intake Manifold Strap Bracket
35 26 -
Bolt at Generator
Generator Lower Support Bracket Bolts 25 18 -
Generator Upper Bracket Bolts at Intake
25 18 -
Manifold & Coolant Bypass housing
Generator Upper Bracket Bolt at Generator 35 26 -
50 + 60 + 37 + 60 +
Intake Camshaft Gear Bolt -
15 15
Intake Manifold Retaining Bolt & Nuts 18 13 -
Intake Manifold Support Bracket Bolt 25 18 -
Interm Shaft Support Bracket Bolts 70 52 -
Oil Filter Adapter to-Oil Pump Bolts 8 - 71
Oil Pan Drain Plug 18 13 -
Oil Pan Flange-to-Cradle Retaining Bolts 50 37 -
Oil Pan Retaining Bolts 20 15 -
Oil Pressure Switch 40 30 -
Oil Pump Rear Cover Bolts 20 15 -
Oil Pump Retaining Bolts 10 - 89
Oil Suction Pipe Retaining Bolts 8 - 71
Pup Converter-to-Exhaust Front Pipe
40 30 -
Retaining Nuts
Rear Timing Belt Cover Bolts 7 - 62
Safety Relief Valve Bolt 30 22 -
Spark Plugs 25 18 -
Starter-to-Engine Block Mounting Bolt 75 55 -
Starter-to-Transmission Mounting Bolt 75 55 -
Timing Belt Automatic Tensioner Bolt 25 18 -
Timing Belt Idler Pulley Bolt & Nut 25 18 -
Transaxle Front Mount Retaining Bolts 50 37 -
Transaxle Front Mount-to-Transaxle
90 66 -
Through Bolt
 Application Nm Lb-Ft Lb-In
Transaxle Mount Assembly Retaining Bolts 37 27 -
Transaxle Mount Bracket Retaining Bolts 50 37 -
Transaxle Rear Mount Retaining Bolts 90 66 -
Transaxle Rear Mount Bracket Retaining
90 66 -
Bolts
Transaxle Rear Mount-to-Bracket Through
90 66 -
Bolt
Transaxle-to-Oil Pan Flange Bolt 50 37 -
Transaxle Torque Coverter Bolts 45 33 -