The Chrysler 2.2 Liter Engine - Specifications

Introduction to the specifications

This page has detailed specs on the 2.2 throttle-body (93 horsepower) and 2.2 Turbo III (224 horsepower) engines used on Chrysler, Dodge, and Plymouth vehicles. Also see our main 2.2 liter engines pages (TBI and turbo). We know there are errors below because it was optically scanned and machine-typed; we are not responsible for the consequences of use or abuse of this information, right or wrong. Proceed at your own risk. Please point out errors to us. (See Centerlining the Turbo III camshaft and the 2.2 turbo engines)

GENERAL

A515 2.2L HPTBI (EDF) A522 2.2L TURBO III (EDS)
Engine assembly part no. 4536606 4536619
Type of engine SOHC inline 4 vertical DOHC inline 4 vertical
Bore 87.5 mm - (same)
Stroke 92.0 mm -
Stroke/Bore ratio 1.051 -
Piston height TDC 0 - 0.648 mm below deck 0.360 mm above - 0.260 mm below deck
Head gasket compressed thickness 1.74 - 1.82 mm -
Volume - piston displacement 2213 cc -
- combustion chamber w/plugs & valves 48.5 - 51.5 cc 57.0 - 60.0 cc
- piston dish+valve cuts 1.83 cc 5.4 - 6.2 cc
- head gasket bore allowance 10.95 - 11.71 cc
- bore chamfer allowance 0.11 - 0.31 cc
- piston chamfer allowance 0.01 - 0.08 cc 0.001 - 0.022 cc
- total clearance 61.40 - 69.32 cc 71.30 - 79.80 cc
Compression ratio
Minimum:1 - Nominal:1 - Maximum:1 8.98 - 9.00 - 10.01 7.9 - 8.3 - 8.8
Spark plug - type/gap Champion RN12YC / 0.035 Champion RN9YC / 0.035 in.
Firing order 1-3-4-2
Valve lash adjustment/cam follower - type Hydraulic/Roller
Assembly weight (includes 4 qts oil & filter) 251.2 Lbs 364.0 lbs

CLEARANCE DATA

Crankshaft - main bearing clearance 0.011 -0.072 mm
- end play 0.05 -0.18 mm
- interference fit sprocket 0.013 -0.063 mm
- key width to sprkt slot clearance 0.01 -0.09 mm
Connecting rod large end - bearing clearance 0.019 -0.075 mm
- side clearance 0.13 -0.38 mm
Balance shaft gear end play N/A 0.100 -0.34 mm
Oil pump - body clearance in block 0.013 -0.114 mm
- outer rotor clearance in body 0.177 -0.331 mm
- shaft clearance in body 0.02 -0.06 mm
- shaft end play 0.025 -0.076 mm
- shaft interference in gear 0.02 -0.06 mm
Piston pin - interference in rod 0.0178 - 0.0429 mm N/A
- clearance in rod N/A 0.012 -0.025 mm
- clearance in piston 0.006 -0.019 mm 0.006 -0.018 mm
- end play N/A 0.04 -1.02 mm
Piston - skirt clearance @ diameter on print 0.013 -0.038mm @ -E" 0.047 -0.073 mm @ "Dl" & "DN"
- skirt clr measured below head surface 28.9 mm- 55.85 mm
- head land clearance (diameteral) 0.898 -1.092 mm
Camshaft - journal to head clearance 0.04 -0.082mm 0.05 -0.100 mm
- end play 0.13 -0.33 mm 0.025 -0.200 mm
- key width to sprocket slot clearance 0.01 -0.09 mm 0.00 - 0.08 mm
- nose to sprocket clearance 0.007 -0.058 mm 0.010 -0.055 mm
Inter, shaft - journal to bushing clearance0.017 -0.080 mm
- end play 0.105 -0.420 mm
- nose to sprocket clearance 0.007 -0.058 mm
- key width to sprkt slot clr 0.01 -0.09 mm
Hydraulic lifter clearance - body to cyl head 0.018 -0.069 mm N/A
- in rocker arm N/A 0.011 -0.042 mm
Valve stem to guide clr - intake (both ends) 0.022 -0.065 mm 0.030 -0.060 mm
- exhaust hot end 0.076 - 0.119 mm 0.300 -0.315 mm
- exhaust cold end 0.051 - 0.094 mm 0.050 -0.080 mm
Rocker arm - to spring retainer - minimum clr 1.25 mm N/A
- to shaft clearance N/A 0.96 - 0.967 mm
Turbocharger rotating aasy - radial clearance N/A 0.076 -0.145 mm
- axial end play N/A 0.013 - 0.081 mm

30A01 - CYLINDER BLOCK

A515 2.2L HPTBI (EDF) A522 2.2L TURBO III (EDS)
Part number (assembly) 4556032 4621029
Main bearing bore - I.D. 63.992 - 64.013 mm
- align, bar dia. @ 21 (70~F) 63.9770 ± 0.0025 mm
- length #1 & #5 25.0 mm
- length #2 & #4 24.0 mm
- length #3 23.48 - 23.53 mm
Cylinder bore diameter finishes @ 21~ (70°F)-
A size 87.468 -87.480 mm N/A
B size 87.481 - 87.493 mm
C size 87.494 - 87.506 mm
D size 87.507 - 87.519 mm
E size 87.520 - 87.532 mm N/A
Cylinder -out of round - maximum 0.025 mm
bore taper after honing - maximum 0.025 mm
bore finish 0.50 -0.88 um
- head oil restrictor P/N N/A 4323808
- head oil restrictor diameter N/A 2.93 - 3.43 mm
Breather vent - nipple P/N N/A 4387304
- bore diameter N/A 15.80 - 15.85 mm
Crankshaft centerline - to block deck surface 237.67 - 237.93 mm
-to chamber @ bottom of bore 86.5 mm
Block deck - flatness 0.012 mm / 51 mm any direction -
- micro finish 2.0 - 3.8 um
Inter, shaft bearing bore -diameter - front 45.97 - 46.03 mm
diameter - rear 22.97 - 23.03 mm
-length - front 20.88 - 20.96 mm
-length - rear 22.0 mm
Plug - oil gallery (2 req'd) - P/N 4556018 - P/N4556022
- core hole (5 req'd) (5/8 in. Ø) (1.625 in. Ø)
Distributor - bore diameter 27.015 - 27.090 mm N/A
- clamp P/N 4179922 N/A
Oil pump bore diameter 36.073 - 36.134 mm
Dowel -cyl head attachment (2 req'd) - P/N 6500402
bal/shft carrier att (2 req'd) - P/N N/A 6500402
crank seal ret att (2/retainer) - P/N 5203466
-clutch/trans hsg att (2 req'd) - P/N 5240849
Dipstick tube hole diameter 10.29 - 10.35 mm
Cross drill hole diameter N/A 3.5 - 4.0 mm

30A01 - TIMING BELT COVER

Cover - upper assembly - P/N 4448634 4442821
- lower assembly - P/N 4667247 4442822
Plug - upper cover - P/N 2094631 N/A
- lower cover - P/N 4448725 N/A
Flap / staple - upper cover - P/N 4343823 / 6033112 N/A
Seal strip - upper cover edge - P/N N/A 4484312 (68 - 72 mm long)
- upper cover edge - P/N N/A 4484313 (178 - 182 mm long)

30A02A - CRANKSHAFT BEARING

Part numbers
- #1. 2. 4, 5 lower 5203355 (CL-66). OPT 4621132 (AL-6M) 5203355
#3 lower 5203376 (CL-66), OPT 4621146 (AL-6M)
- #1. 2, 4, 5 upper 5203355 (CL-66). OPT 4621132 (AL-6M) 5203355
#3 upper 5203369 (CL-66). OPT 4621139 (AL-6M)
- Wall thickness @ 90° to parting line - CL-66 1.977 - 1.984 mm- AL-6M 1.976 - 1.984 mm
Bearing length
-#1. 2. 4, 5 21.36 - 21.61 mm
#3 27.80 - 27.87 mm
Flange thickness- #3 2.09 - 2.14 mm
Bearing material - CL-66 Pb/Al, Steelbacked; MS-5557
- AL-6M Pb/Al, Steelbacked; MS-7651
Liner thickness at center - #1, 2, 3, 4, 5 0.13 - 0.50 mm
Bearing inspection process standard PS-771 & PS-1159
Crush height at total load 0.020 - 0.060 mm @ 4900 N
Oil hole - dia. - #1. 2, 3, 4, 5 6.25 - 6.75 mm
Sizes released STD, .025. .050, .25. .275, .300 mm U/S
Shell taper - measured from parting line ( less than center thickness )
#1, 2, 4, 5 - CL-66 0.007 - 0.015 mm
#3 - CL-66 0.0076 - 0.0152 mm
#1, 2, 4, 5 - AL-6M 0.007 - 0.017 mm
#3 - AL-6M 0.0076 - 0.0176 mm

30A02A - CRANKSHAFT BEARING CAP

Part numbers - #1. 2, 3, 4, 5 4483261, 4483262, 4483263, 4483264. 4483265
Part number 4448496 4536082
Material Nodular Cast Iron MS-4561 Steel MS-4925
Number of flange attachment holes 8
Number, of main bearings 5
Thrust taken by #3 bearing
Main bearing journal - diameter 59.987 - 60.013 mm
- out of round 0.008 mm
- taper - maximum 0.008 mm
- finish - maximum 0.38 um
- fillet radii 1.45 - 1.65 mm
Main bearing thrust surface finish - maximum 0.63 um front / 0.38 um rear
Main bearing journal length between thrust surfaces
- #1 25.87 - 26.13 mm
#2, 4, 5 27.87 - 28.13 mm
#3 27.96 - 28.04 mm
Crankpin - diameter 49.979 - 50.005 mm
- out of round 0.008 mm
- taper - maximum 0.008 mm
- finish - maximum 0.38 um
- length between thrust surfaces 25.9 - 26.1 mm
- fillet radii 1.45 - 1.65 mm
Center bearing runout - supported at front &
rear main (maximum) 0.08 mm
Crankshaft diameter - sprocket hub 25.475 - 25.500 mm
- front seal journal 28.462 - 28.538 mm
- rear seal journal 90.920 - 91.080 mm
Crankshaft seal journal finish 0.15 - 0.63 um
Angle between crank throws 180°
Centerline main to centerline crankpin 45.92 - 46.08 mm
Imbalance - maximum 25 gm-cm (0.35 in-oz)
Index tolerance on sprocket keyway ± 0° 20'
Flange - O.D. circular runout 0.08 mm
- face flatness 0.025 mm
- hub O.D. 47.95 - 48.00 mm
- hub concentricity O.D. 0.05 mm
- pilot I.D. 33.981 - 34.019 mm
- pilot I.D. concentricity 0.09 mm
Sprocket fillet radii 1.45 - 1.65 mm

30A02A - CRANKSHAFT SEAL & RETAINER

FRONT: Seal Part number 4273275
Seal material MS-BZ726
Retainer Part number 4387579 4484390
Retainer bore diameter 41.225 - 41.275 mm
Assembly Part number 4387580 4536309
REAR: Seal Part number 5203590
Seal material MS-BZ820
Retainer Part number 5214782
Retainer bore diameter 110.97 - 111.02 mm
Assembly Part number 5214784

30A02A - CRANKSHAFT SPROCKET

Part number 4483298 4442973
Number of teeth 20
Pitch diameter (reference) 60.6380 mm
Reamed I.D. 25.437 - 25.462 mm
Tooth - finish - maximum 1.6 um
- profile drawing 4483298 4442964 (20T RPP)
Material MS-589-A-2 MS-2282
Pilot insert - P/N N/A 4483486
Key slot width 4.03 - 4.08 mm
Sprocket key - P/N 6500150
- width 3.99 - 4.02 mm.

30A02A - TIMING BELT

Part number 4387549 4484494
Number of teeth 124 131
Tolerance - each edge - maximum 0.75 mm T.I.R.
Belt material/color ident/vendor MS-EB119/green/Gates HSN/none/Pirelli
Pitch 9.525mm (0.375 in.)
Belt width 23.3 - 24.3 mm 29.2 - 30.8 mm

30A02A - TIMING BELT TENSIONER

A515 2.2L HPTBI (EDF) A522 2.2L TURBO III (EDS)
Part number 4315705 4484464
Tension on Burroughs gauge - new belt 50 -70 lbs 100 - 110 lbs
Pulley - flat diameter 71.5 - 72.5 mm 75.8 - 76.2 mm
- pitch diameter (reference) 75 mm 77.5 mm
- width at pitch diameter 25.7 - 26.3 mm 34.5 - 36.1 mm

30A02A - TIMING BELT IDLER

Part number N/A 4484465
Pulley - flat diameter 59.8 - 60.2 mm
- pitch diameter (reference) 61.5 mm
- width at pitch diameter 34.8 - 36.3 mm

30A02A - BALANCE SHAFT SPROCKET-CRANKSHAFT

P/N N/A 4483486
Material MS-589-B3
Number of teeth / pitch 36 / 7.774 mm
Pitch diameter 89.2 mm

30A02A - BALANCE SHAFT DRIVE CHAIN

P/N N/A 4273260
Type Single row, roller
Length between centers 126.30 - 126.55 mm @ 156.6 N load
Pitch 7.774 mm (non-adjustable)

30A02B - BALANCE SHAFT CARRIER

Carrier assembly - P/N N/A 4556231
Bearing diameter - front 25.06 - 25.08 mm
- rear 42.06 - 42.08 mm
Bearing surface finish - front / rear - maximum 0.75 / 1.0 um
Rear bearing - P/N 4273252
- material Pb/Al. steelbacked; MS-7651, OPT MS-5557
- crush height 0.000 - 0.048 mm @ 2560 N
- press fit 0.12 - 0.19 mm
- press in load - minimum 2600 lb.
Plug - oil feed (1 req'd) - P/N 5203517 (7/16 in. Ø)
Cover - carrier gear - P/N 4323039
Dowel - carrier gear cover att (2 req'd) - P/N 5203466
Trough - carrier gear cover - P/N 4323041
Rear cover - P/N 4323043

30A02B - BALANCE SHAFT

Driver (OR) - P/N N/A 4621088
Driven (ON) - P/N 4621089
Material Nodular Iron, MS-3996A
Journal - diameter - front 24.99 - 25.01 mm
- diameter - rear 41.99 - 42.01 mm
- roundness & taper 0.012 mm T.I.R.
- finish (front & rear) - maximum 0.25 um
Imbalance - maximum 7.68 in-oz.

30A02B - BALANCE SHAFT GEAR

Driver (DR) - P/N N/A 4343783
Driven (DN) - P/N 4343785
Type. 30 teeth - DR / ON Right helix / Left helix
Material MS-891
Thrust surfaca finish - maximum 0.63 um
Measurement over two 3.175 mm diameter balls 62.710 - 62.799 mm
Gear tooth root hardness @ 0.75 mm minimum depth HRC 48 - 52
Key - P/N 6500150

30A02B - BALANCE SHAFT DRIVER SPROCKET

P/N N/A 4483485
Material MS-589-B3
Number of teeth / pitch 18 / 7.774 mm
Pitch diameter 44.77 mm

30A02B - BALANCE SHAFT CHAIN TENSIONER & GUIDE

Tensioner - P/N N/A 4343662
Clearance, chain to tensioner,
Apply 5.5 - 6.5 lb tangental load w/1 mm shim 1 mm over 70 mm span
Guide, non-adjustable - P/N 4343660

30A03 - CONNECTING ROD

Part number - assembly - with warm formed cap 4387736 4556210
- with hot forged cap 4387737 N/A
Bearing bore - center to pin bore center 150.95 - 151.05 mm
- finish - maximum 1.5 um
- diameter 52.992 - 53.008 mm
Bearing end width 25.72 - 25.77 mm
Piston pin - bore finish - maximum 3.2 um 1.5 um
- bore diameter 22.840 - 22.860 mm 24.587 - 24.638 mm (w/o bushing)
- end width 25.70 - 25.78 mm
- bore to bearing bore parallelism 0.08 mm 0.02 mm
- bore to bearing bore twist 0.08 mm 0.04 mm
Bolt hole I.D. 9.89 - 9.93 mm
Material MS-405
Hardness 229 - 269 HRB
Assembly mass - large end 514.5 - 518.5 g 512.5 - 516.5 g
- small end 127 - 151 g 189.2 - 191.2 g

30A03 - CONNECTING ROD PISTON PIN BUSHING

Part number N/A 4536094
Material Bronze on steel; MS-1900, OPT MS-2164
Thickness - before rod assembly 1.127 - 1.254 mm
I.D. - finished rod assembly 22.895 - 22.903 mm
I.D. finish - maximum 1.5 um

30A03 - CONNECTING ROD ATTACHMENT

Bolt - P/N 4448934 (double knurll) 4536307
- thread size 3/8-24 UNF-3A (rolled)
- material - property class analysis MS-3049
- shank diameter 0.343 - 0.348 in.
- length 2.22 - 2.26 in. 2.06- 2.10 in.
- hardness 34- 38 HRC 39-43 HRC
Nut - P/N 4227678 (flanged) 4536306 (no flange)
- thread size 3/8-24 UNF-3B
- material - property class analysis MS-5820
- hardness 28-34HRC 30-36HRC

30A03 - CONNECTING ROD BEARING

Part number 4536284 (AL-6M), OPT 5203390 (CL-66) 4105240 (H-24)
Bearing material Pb/Al, Steelbacked Cu/Pb, Steelbacked
MS-7651, OPT: MS-5557 MS-4790
Wall thickness at 90° to parting line length 570 1.476 - 1.484 mm 1.471 - 1.484 mm
OPT 1.477 - 1.484 mm
Bearing length 19.90 - 20.16 mm
Liner thickness at center of bearing 0.13 - 0.50 mm
Inspection process standard PS-771 & PS-1159
Sizes released STD; 0.025, 0.050, 0.250, STD; 0.050. 0.250, 0.275,
0.275. 0.300 mm U/S 0.300 mm U/S
Shell taper - measured from parting line 0.005 - 0.013 mm
Crush height at total load 0.045 - 0.085 mm @ 2450 N

30A03 - PISTON

Part number 4556180 4315268
Skirt sizing dia., below head surface 28.9mm 55.85mm
- A size 87.442 -87.455 mm 87.407 -87.420 mm
- B size 87.455 -87.468 mm 87.420 -87.433 mm
- C size 87.468 -87.481 mm 87.433 -87.446 mm
- 0 size 87.481 -87.494 mm 87.446 -87.459 mm
- E size 87.494 -87.507 mm 87.459 -87.472 mm
Skirt taper
- max. dia., increase over sizing dia. 0.00 - 0.015 mm Barrel profile
- bottom dia., decrease over sizing dia. 0.025 - 0.075 mm
Ring groove width - upper & 2nd 1.528 - 1.553 mm 1.530 - 1.550 mm
- 3rd 4.010 - 4.035 mm
3.010 - 3.030 mm
Centerline piston pin to top of head (Piston compression height) 40.412 - 40.540 mm 40.80 - 40.90 mm
Overall height 71.05 - 71.55 mm 65.55 - 66.15 mm
Pin bore - diameter 22.8892 - 22.8968 mm 22.889 - 22.896 mm
- to skirt squareness 0.001 mm/mm 0.0005 mm/mm
- offset to major thrust side 1.5 mm 0.9 - 1.1 mm
Finished mass . 430 - 440 g 415 - 425 g
Type of piston - aluminum Cast w/steel struts-4323604 Forged
Material - aluminum (excl struts) MS-3012 MS-7438
Hardness - aluminum 95 - 125 BHN 90 - 120 BHN
Coating Tin plate, PS-1751
Sizes released STD; 0.50 mm 0/S STD

30A03 - PISTON PIN

A515 2.2L HPTBI (EDF) A522 2.2L TURBO III (EDS)
Part number 1947351 4315352
- finished - measured at 21°C 22.8778 - 22.8829 mm 22.878 - 22.883 mm
Length 74.80 - 75.82 mm 63.7 - 64.0 mm
Wall thickness - minimum 3.38 mm 4.389 mm
Surface finish - maximum 0.15 um 0.07 um
Material MS-301 Mahle-class L (17Cr3)
Mass - calculated - nominal 126.8 g 129.2 g

30A03 - PISTON PIN RETAINER

Part number N/A 4483495
Material MS-5795
Wire diameter 1.56 - 1.64 mm

30A03 - PISTON RING - UPPER

Part number 4323259 4315339
Width 1.475 - 1.490 mm
Radial wall thickness 3.72 - 3.96 mm 3.35 - 3.70 mm
Tangential tension @ 87.5 mm gage diameter 17 - 29 N 8.2 - 12.3 N
Flatness 0.05 mm N/A
Concentricity (1.0. to 0.0.) 0.25 mm 0.18 mm
Gap @ 87.5 mm gage diameter 0.25 - 0.51 mm 0.3 - 0.5 mm
Type No twist
Face - coating - Molybdenum PS-4494B (Goetze MP96A)
- finish - maximum Barrel lap 16 um
Inspection standard PS-1029 N/A
Sizes released STD; 0.50 mm 0/S STD
Identification markings Sealed Power GDE Z MP96A TOP K
Perfect Circle o Muskegon

30A03 - PISTON RING - INTERMEDIATE

Part number 5203330 4315270
Width 1.46- 1.49 mm 1.475 - 1.490 mm
(1.5 max after coating)
Radial wall thickness 3.87- 4.11 mm 3.35 - 3.70 mm
Tangential tension @ 87.5 mm gage diameter 23.5- 36.0 N 7.5 - 11.2 N
Flatness 0.05 mm N/A
Concentricity (1.0. to 0.0.) 0.25 mm 0.18 mm
Gap @ 87.5 mm gage diameter 0.28- 0.53 mm 0.3 - 0.5 mm
Type Reverse twist No twist
Coating (all over) PS-863 B4 (Lubrite) N/A
Face - finish Turned 3-16 um
- taper 1°30' - 2°30' 1°00' - 2°00'
Material MS-3744(Goetze std)
Sizes released STD; 0.50 mm 0/S STD
Identification markings - Sealed Power GOE Z TOP
Perfect Circle o Muskegon

30A03 - PISTON RING - LOWER

Part number 4201962 4442959
Width - maximum 0.49 mm 2.975 - 2.990 mm
Radial wall thickness 2.72 -2.88 mm 2.65 -3.00 mm
Tangential tension @ 87.5 mm gage diameter N/A 38.0 -53.0
Concentricity (1.0. to 0.0.) N/A 0.18 mm
Gap @ 87.5 mm gage diameter 0.25 -1.27 mm 0.25 -0.50 mm
Free gap 0.77 - 3.94 mm N/A
Surface treatment PS-1129 (Goetze)
Face coating PS-1217 Chrome
Chrome thickness - minimum 0.05 mm 0.06 mm
Face finish - maximum Lapped or Ground 3 um
Number per piston 2 1
Material MS-2015 (Goetze std)
Hardness HR 30N-68-72 N/A
Width - 2 rails+spacer - maximum 4.005 mm (see above)
Sizes released STD; 0.50 mm 0/S STD

Added 3/18/03:

30A03 — PISTON RING SPACER - LOWER

A515 2.2L HPTBI (EDF) A522 2.2L TURBO III (EDS)
Part number 4201965 N/A
Tangential. tension @ 87.5 mm gage diameter 22.5 - 48.5 N
Material HS-3458A or MS-605
Width 3.73 — 3.92 mm
Free gap 0.0 - 6.4 mm
Stock thickness 0.435 — 0.485 mm
O.D. @ 0 gap 86.91 — 87.53 mm
Identification markings o —Perfect Circle 1 - Muskegon
.S or No mark -Sealed Power H - Hastings
Sizes released STD; 0.50 mm 0/S

30A04A - CAMSHAFT

SOHC - intake & exhaust - P/N 4387850 N/A
DOHC - intake / exhaust — P/N N/A 4442937 / 4442938
- intake / exhaust - assy P/N N/A 4442940 / 4442941
Material MS-3996—A
Bearing journal diameter 34.939 — 34.960 mm 47.925 — 47.950 mm
Bearing journal length - #1 (w/o chamfers) 28.09 - 34.41 mm 26.7 - 27.3 (w/5mm slot)
— #2, 3, 4 17.25 — 17.75 mm N/A
- #5 thrust - minimum 14.6 mm N/A
- #2. 3, 4, 5 — nominal N/A 16.0 mm (w/o chamfers)
- #6 thrust - nominal. N/A 19.0 mm (w/o chamfer)
SOHC - width between thrust surfaces 21.45 - 21.55 mm N/A
DOHC - width between intake cam thrust surfaces N/A 12.2 - 12.3 mm
DOHC - width between exhaust cam thrust surfaces N/A 10.2 - 10.3 mm
Bearing journal finish - maximum 0.40 um 0.38 um
Lobe - basecircle diameter - intake & exhaust 35.4057 — 35.6597 mm 33.7392 - 33.8192 mm
- basecircle runout - maximum 0.050 mm T.I.R. 0.020 mm T.I.R.
- centerline to key slot error ± 0.5°
- length 15.9 — 17.4 mm 16.0 - 17.5 mm
- surface finish - maximum 0.50 um 0.38 um
Lobe surface hardness - 180° of base circle 51 HRC (minimum) N/A
- 180° including nose 55 HRC (minimum) N/A
- DOHC camshafts N/A 50 - 55 HRC
Depth of lobe hardness - 180° of base circle 0.76 - 3.81 mm N/A
- 180° including nose 0.76 - 5.59 mm N/A
- DOHC camshafts N/A 1.0 mm
Core & brg journal. hardness 229 - 302 HB 255 - 311 HE
Cam lift - intake & exhaust 6.23289 mm 4.80000 mm
Valve lift - intake & exhaust 10.992 mm 8.550 mm
Thrust surface finish — maximum 0.80 um
Key offset to #1 lobe 47.2° (exhaust lobe)
Sprocket key slot width 3.96 - 3.99 mm 3.94 - 3.96 mm
Valve duration - intake - nominal 236° 190°
- exhaust - nominal 232° 188.5°
Intake opens - nominal. 0° (TDC) 25° ATDC (at 1.27 mm lift)
Intake closes — nominal 56° ABDC 35° ABDC (at 1.27 mm lift)
Valve overlap - nominal -32.5° (at 1.27 mm lift)
Exhaust opens - nominal. 44° BBDC 16° BBDC (at 1.27 mm lift)
Exhaust closes — nominal 8° ATDC 7.5° BTDC (at 1.27 mm lift)
SOHC - centerline (#1 intake) - nominal 118° N/A
DOHC - centerline (#1 intake) - nominal N/A 121°
- centerline (#1 exhaust) - nominal N/A 104°
Centerline designed tolerance ± 2°
Journal diameter — front seal 34.939 — 34.960 mm 37.84 — 38.00 mm
— real seal 34.86 — 35.02 mm N/A
Journal finish - front seal 0.15 - 0.50 um 0.20 - 0.63 um
- rear seal 0.15 — 0.63 um N/A
Shaft diameter @ aprocket hub 23.487 - 23.513 mm 25.375 - 25.390 mm
Sizes released (journal diameter) STD; 0.50 mm 0/S STD

30A04A - CAMSHAFT BEARING CAP

Part number - #1, 5 5203731, 5203737 N/A
— #2, 3, 4 (w/oil squirt slots) 5203733, 5203734, 5203735
- OPT: #2, 3, 4 (w/o oil slots) 5281132, 5281134, 5281136
Material - die cast aluminum MS-2410D
Cap bore bearing length - #1, 2, 3, 4 17.3 - 17.7 mm
Parting line surface to flat & true within 0.025 FIR

30A04A - CAMSHAFT SEAL

Part number (front) 4105395 4424059
Material MS-BZ726 N/A
Part number (rear) 4343903 N/A
Material MS-BZ725
Pressed ball plug - front oil seal - P/N N/A 4442117
- depth N/A 34.5 - 36.0 mm
Screw plug — rear oil meal — P/N N/A 4424096

30A04A - CAMSHAFT RETAINER

A515 2.2L HPTBI (EDF) A522 2.2L TURBO III (EDS)
Part number - intake camshaft N/A 4484404
Intake retainer width 11.950 - 12.025 mm
Part number - exhaust camshaft N/A 4484405
Exhaust retainer width 9.950 - 10.025 mm

30A04A - CAMSHAFT SPROCKET

SOEC - P/N 4387557 NIA
DOHC - intake - P/N N/A 4442871
- exhaust assy P/N N/A 4484263
Number of teeth 40
Pitch diameter (reference) 121.276
Reamed I.D. 23.520 — 23.545mm 25.40 — 25.43 mm
Tooth - finish - maximum 1.6 um
— profile drawing 4387557 4442965
Material MS-588-B-2 MS—2282
Key slot width 4.03 - 4.08 mm 3.99 - 4.04 mm
Sprocket key — P/N 6500150 4442045
— width 3.99 — 4.02 mm 3.96 — 3.99 mm

30A04B - INTERMEDIATE SHAFT

Part number 4343428 4556214
Pitch diameter of gear 33.093 mm
Bearing journal -diameter - front 42.670 - 42.703 mm
...—diameter — rear 19.670 — 19.703 mm
- length - front - nominal 20.0 mm
- length - rear - nominal 22.5 mm
— finish 0.40 - 2.50 um
Gear - blank hardness 229 - 286 HB
- tooth forming Bobbed Bobbed & Shaved
- tooth flank finish - maximum 2.03 um 0.64 um
Seal journal - diameter 34.975 — 35.025 mm
— finish 0.15 — 0.63 um
Shaft diameter @ sprocket hub 23.487 - 23.513 mm

30A04B - INTERMEDIATE SHAFT BUSHING

FRONT: Part number 4387691
Bearing finish I.D. after reaming 42.72 - 42.75 mm
...O.D. (free state) 46.32 - 46.55 mm
...Length incl l.1/1.9x15° O.D. chamfer 18.5 - 19.5 mm
...Material (Babbitt on steel) MS-1680, OPT MS-2012
REAR: Part number 5203468 4621161 (double slot)
Bearing finish 1.0. after reaming 19.72 - 19.75 mm
0.0. (free state) 23.32 —23.55mm
...Length incl l.1/1.9x15° 0.0. chamfer 20.5 -21.5 mm
...Material (Babbitt on steel) MS-1680, OPT MS-2012
...Oil slot angle relative to shaft centerline N/A 29.5° - 30.5°
...Oil slot min. width in babbitt after forming N/A 1.27 mm

30A04B - INTERMEDIATE SHAFT SEAL & RETAINER

Assembly - P/N 5203325 4484070
Seal — P/N 4105388
- material MS-BZ726
Retainer — P/N 5203319
- seal bore diameter 51.975 - 52.025 mm

30A04B - INTERMEDIATE SHAFT SPROCKET

Part number 4387557 4443000
Number of teeth 40 30
Pitch diameter (reference) 121.276 90.96
Reamed 1.D. 23.520 - 23.545 mm
Tooth - finish - maximum 1.6 um
- profile drawing 4387557 4442966
Material MS-588—B-2 MS-2282
Key slot width 4.03 - 4.08 mm
Sprocket key — P/N 6500150
- width 3.99 — 4.02 mm

3OAO5A - ENGINE LIFT BRACKET

Right side — P/N N/A 4484376
Left side — P/N N/A 4484377
Part number (w/o guides, seats, plugs or studs) 4105783 4484450
Material MS—6876 (AA319 alloy) MS-6876 (AS 7 U3 alloy)
Combustion chamber design Fastburn Hemispherical
Camshaft — bearing bore diameter 35.000 - 35.021 mm 48.000 — 48.025 mm
— bore centerline to deck 158.37 - 158.73 mm 98 mm (reference)
Intake to exhaust cam bore centerline N/A 100 mm (reference)
Valve seat counterbore diameter - intake 42.275 — 42.300 mm 35.800 — 35.625 mm
— exhaust 36.715 — 36.740 mm 32.500 — 32.525 mm
Intake & exhaust valve guide counterbore dia. 12.467 - 12.500 mm 11.500 - 11.513 mm
Reference valve angle - intake 7.5° 15.5°
- exhaust 7.5° 14.0°
Seal bore diameter - front 51.98 - 52.02 mm 50.000 - 50.039 mm
- rear 53.23 - 53.27 mm N/A
Rocker shaft bore diameter N/A 20.96 - 21.09 mm
Coolant outlet diameter 36.5 - 37.0 mm 41.75 - 42.25 mm
Plug - core (2 req�d) — P/N 4556020 (1.25 in. ø) 4424085 (49 mm ø)
- oil. gallery (2—EDF,1—EDS) — P/N 4556018 (5/8 in. ø)
— (1 req�d) — P/N N/A 5203517 or 4556017
(7/16 in. ø)
— oil gallery (1 req�d) - P/N N/A 4484426 (8 mm ø)
Block face finish - maximum 2.0 um
Specified hardness (BHN) 70 100 — 130
Valve lash adjuster bore diameter 15.931 - 15.969 mm N/A
Cross drill hole diameter N/A 3.5 - 4.0 mm

3OAO5A - CYLINDER HEAD GASKET

Part number 5281064 4424060

3OAO5A - WATER BY-PASS TUBE

Assy - P/N 4273489 N/A
Bracket - P/N 5281186

30A05B - CYLINDER HEAD) COVER

SOHC - cover assy - P/N 4343496 N/A
- curtain — P/N 4667174
- curtain retainer - P/N 4387331
DOHC - intake cam - P/N N/A 4484462
- exhaust cam - P/N 4484463
- spark plug cover - P/N 4442807
Gasket - P/N N/A 4484489
End seals - P/N 5214479 N/A
Oil fill cap — P/N 4621012 4484490

30A06 - INTAKE VALVE

Part number 4298137 4484421
Material MS-3049 HNV 3
Head O.D. 40.47 — 40.73 mm 33.76 — 34.00mm
Face — angle (from valve axis) 45.0° — 45.5° 45.25° -45.75°
- finish - maximum 0.63 um 0.8 um
Length — overall 113.93 — 114.57 mm 145.3 — 145.7mm
Stem - diameter 7.935 - 7.953 mm 6.955 — 6.970mm
- finish - maximum 0.3 um 0.2 um
- tip finish - maximum 0.5 um
- runout with seat - maximum T.I.R. 0.04 mm 0.03 mm
— coating Flash chrome (PS-3832)
Sizes released STD;0.15, 0.40, 0.80 mm 0/S STD

30A06 - EXHAUST VALVE

Part number 4298142 4484422
Head material MS—3262—B—1 (21—2N) MS—6788 (Inconel. 751)
Head 0.D. 35.275 — 35.525 mm 29.13 — 29.40 mm
Face — angle (from valve axis) 45.0° - 45.5° 45.25° — 45.75°
— finish - maximum 0.63 um 0.8 um
Length — overall 114.55 — 115.19 mm 143.5 — 143.9 mm
Stem — material MS-374 or modified MS-2249 Steel-HNV 3
— diameter - cold end 7.906 - 7.924 mm 6.935 - 6.950 mm
- diameter — hot end 7.881 - 7.899 mm 6.6 - 6.7 mm
- finish - maximum 0.3 um 0.2 um
- tip finish - maximum 0.5 um
— runout with seat - maximum 0.04 mm T.I.R. 0.03 mm
...— coating Heavy chrome (PS-3832)
Sizes released STD; 0.15, 0.40, 0.80 mm 0/S STD

30A06 - VALVE STEM SEAL

Part number 4201332 4424030
Material BZ720 N/A
Sizes released STD; 0.15, 0.40, 0.80 mm 0/S STD

30A06 — VALVE SEAT

A515 2.2L HPTBI (EDF) A522 2.2L TURBO III (EDS)
(as installed dimensions)
Intake — P/N 5203472 4442763
- seat major diameter 40.22 - 40.48 mm 33.75 - 34.25 mm
- seat width 1.75 - 2.25 mm N/A
— seat angle from valve axis 44.5 — 45.0° 44.75° — 45.25°
- face finish - maximum 1.25 um 0.4 um
— material MS-6946 Goetze PMF 4
- sizes released STD; 0.20 mm 0/S STD; 0.127 mm 0/S
Exhaust — P/N 5203792 4442903
- seat major diameter 34.61 - 34.87 mm 29.15 - 29.65 mm
- seat width 1.50 - 2.00 mm N/A
— seat angle from valve axis 44.5 — 45.0° 44.75° — 45.25°
— face finish - maximum 1.25 um 0.4 um
- material MS-6883, OPT MS—7233 Goetze PMF 15
- sizes released STD; 0.20 mm 0/S STD; 0.127 mm 0/S
Intake & Exhaust - maximum T.I.R. runout 0.05 mm 0.07 mm
- maximum out of round 0.013 mm

30A06 - VALVE GUIDE

(as installed dimensions)
Intake — P/N 4483714, OPT 4621122 4484408
Exhaust — P/N 4483711, OPT 4621125 4484408
Intake & Exhaust - material — powder metal MS-8328, OPT MS-8915 MS-7843
— finished 1.D. 7.975 — 8.000mm 7.000 — 7.015 mm
...— 1.D. finish 1.6 — 5.0 um 1.6 um (maximum)
- height above head boss 8.5 - 9.5 mm 6.3 - 7.3 mm
...— sizes released STD; 0.025 mm 0/S STD; 0.127 mm 0/S

30A06 - VALVE SPRING

Part number (assembly) 4448305 4442213
Material MS-820 BS 2803 730 A65 HD
Number of coils - total 6.50 6.99 - 7.01
— active (approximate) 4.63 5
Wire diameter 4.71 — 4.76 mm 4.712 — 4.788 mm
Free length 54.9 mm 53.2 mm
Solid height — maximum 29.6 mm 32.7 mm
Load - valve closed 480 - 534 N @ 41.9 mm 513 — 567 N @ 44.0 mm
- valve open 890 — 961 N @ 31.0 mm 1133 - 1227 N @ 34.2 mm
Inside diameter 25.65 - 26.15 mm 20.41 - 20.91 mm
Maximum out—of-plumb from either end 2.0 mm 1.65 mm
Color Green None

30A06 - VALVE SPRING SEAT

Part number 5203474 4484407
Material MS—482 MS—501A
Thickness 0.67 - 0.93 mm 0.585 - 1.085 mm

30A06 - VALVE SPRING RETAINER

Part number 5203578 4424033
Material MS-3413 or MS-3414 Al killed BS 970: 605M36, OPT 606M36
Hardness HR 15N 82-85 N/A

30A06 - VALVE LOCK

Part number — intake/exhaust 4201349 / 5203577 4424035/ 4424034
Material MS-3414 N/A
Number of beads — intake/exhaust 1 / 4 1/3

30A06 - VALVE LASH ADJUSTER

Part number - Stanadyne 4105348 N/A
Body material MS-3958
Type Hydraulic
Diameter 15.900 - 15.913 mm
Dry lash 0.62— 1.52 mm
Leak down 5 -25 seconds
30A06 - ROCKER ARM
Part number - Toledo Stamping 4387269 N/A
- Welles Manufacturing 4387270
Fulcrum Ratio — base circle 1.615:1
— nose 1.762:1
Roller diameter 17.75 - 17.80 mm
Hardness - valve tip pad & lash adj. socket 50 RC minimum
Ear depth on valve tip pad - minimum 1.5 mm

30A06 - ROCKER ARM WITH HYDRAULIC ELEMENT

Part number - left / right hand assy - INA N/A 4484379 / 4484380
Shaft bore diameter 21.00 — 21.02 mm
Roller diameter 17.75 - 17.80 mm
Roller width 12.75 - 12.80 mm
Hydraulic element - bore diameter 11.005 - 11.025 mm
- body diameter 10.983 - 10.994 mm

30A06 - ROCKER SHAFT

Intake / exhaust shaft —P/N N/A 4484373 / 4484419
...Intake / exhaust shaft —assy P/N 4424011 / 4484424
-diameter 20.967 - 20.980 mm
...—end plug (2/shaft) P/N 5203517 or 4556017 (7/16 in. ø)
...Intake shaft - end spacer - P/N 4424061
- end spacer thickness 1.8 — 1.9 mm

30A06 - ROCKER SHAFT RETAINER

Intake & exhaust shaft — P/N N/A 4424007
- length 20.8 - 21.0 mm
Intake shaft end — P/N N/A 4424008
- length 30.75 — 31.25 mm
Exhaust shaft end retainer - P/N N/A 4484423
- length 23.75 - 24.25 mm

30A07 - WATER BOX & THERMOSTAT

Choke thermostat-permanent bypass - P/N 4105404, OPT:4387819
Coolant temperature 195° F
Connector - water outlet - P/N 5281063 4442618
— gasket — P/N 4179895 4442621
Water box assy - P/N N/A 4442998
- gasket - P/N N/A 4315333

30A07 - WATER PUMP

Assembly — P/N 4483451, OPT:4621171 4483451
Impeller diameter 77 mm
Shaft & ball brg assy - P/N 4621174 (w/4621171) N/A
Shaft & roller brg assy — P/N 4483410 (w/4483451)
Gasket - pump assy inlet - P/N 5203542
- pump housing to body - P/N 4387459
Deflector assy - pump inlet - P/N N/A 4484321
Spacer - pump lower att to block - P/N N/A 4556247

30A08A - OIL PAN

Assembly — P/N 4448712 4448603
Capacity including filter 4 quarts (3.8 liters)
Seal - front - P/N 4387478
- rear — P/N 5203778
Gasket - right - P/N 4387475
— left — P/N 4387476

30A08B - OIL PUMP

Assembly — P/N 4323626 4442298
Body - block pilot diameter 36.02 - 36.06 mm 
- rotor housing diameter 63.017 — 63.094 mm 
- rotor housing depth 24.028 - 24.054 mm 
- shaft bore diameter 13.88 - 13.91 mm . 
Rotor thickness 23.978 -24.003 mm
(0.944 — 0.9445 in.)
 
Outer rotor diameter 62.763 - 62.840 mm 
Shaft diameter 13.85 - 13.86 mm 
Gear - P/N 5203105 4556215
- hardness 229 - 286 HB 248 - 286 HB
- shaft bore diameter 13.80 - 13.83 mm  
- tooth flank surface finish - maximum 2.0 um 0.64 um
Spring - pressure relief - P/N 2402473
- free length Approx. 1.95 in.

30A08B - OIL SUCTION TUBE

Assembly - P/N 4387360 4387675
Seal to oil pump - P/N 6032920

30A10A -. INTAKE MANIFOLD

A515 2.2L HPTBI (EDF)
Assembly - no EGR — P/N 4621027 4484413
- EGR — P/N 4448618 N/A
Manifold material MS-2418, OPT MS-2414F
Gasket (2 req�d) —P/N N/A 4484412
PCV nipple — P/N 4343761 6034239
EGR cover plate -P/N 3671447 N/A
EGR gasket - P/N 4300297 N/A

30A103 - EXHAUST MANIFOLD

Part number - assembly 4621028, OPT 4273099 w/plug 4484410
Manifold material MS-3760B MS-4062B
Gasket - intake & exhaust - P/N 5214650 N/A
- exhaust only - P/N N/A 4484411

30A113 - RIGHT ENGINE MOUNT

Part number 4556011 (US) or 4556013 (MEX) 4442962

30B10C - AIR HEATER

Part number 5203338 N/A

30311 - OIL LEVEL INDICATOR & FILTER

Part number -indicator 4536071 4621111
...’tube assy 4387575 4442916
...’tube bracket N/A 4442914
...—filter assy (full flow type) 5281090

30B12A - CRANKCASE VENT SYSTEM

PCV (positive crankcase ventilation) valve — P/N 4315405 3671076
TEE — 0.020 in. orifice - P/N 4300267 N/A
Hose - PCV valve — P/N 4315702 N/A
- TEE to intake manifold - P/N 4315703 N/A
- PCV valve to cyl head cover - P/N 4315704 N/A
- PCV valve to a/clnr - P/N 4343477 N/A
- PCV valve to TEE - P/N 4343851 N/A
- separator to cyl block. - P/N N/A 4621091
- PCV valve to intake manifold - P/N N/A 4621166
Adapter - PCV valve to oil separator - P/N N/A 4621020
Connector - adapter to a/clnr tube — P/N N/A 4621021
Tube assy - adapter to a/clnr - P/N N/A 4621022
Clip (front / rear) - tube to a/clnr support - P/N N/A 4621023 / 4621024
Oil separator assy / support bracket - P/N N/A 4621033 / 4621034

30C09 - TURBOCHARGER

Type N/A Garrett TB0377
Assembly - P/N 4484461
Compressor housing A/R: 0.52
Turbine housing A/R: 0.48
Center housing 180° watercooled jacket
Rotating assembly imbalance @ shaft speed - maximum 1.0 G @ 60,000 RPM
Static actuator calibration, travel @ pressure 0.015 in. @ 6.1 — 7.1 PSIG
Exhaust elbow - P/N 5281143
- material MS—4062B
- nominal outlet diameter 2.50 in.
Support bracket — P/N 4484327
Pipe - turbo compressed air to charge cooler - P/N 4442856

30C09 - TURBOCHARGER OIL PLUMBING

Oil inlet -tube assy (5/16�) md. support clip - P/N N/A 4442846
...Oil return -tube - P/N N/A 4484085
...—hose — P/N N/A 4105457
-gasket — P/N N/A 4227980
-tube in cyl block - P/N N/A 4105456
-hose insulator - P/N N/A 5281164

30C09 - TURBOCHARGER COOLANT PLUMBING

Coolant inlet - tube assembly (3/8�) - P/N N/A 4442839
- support bracket - P/N N/A 4442850
Coolant return - tube assembly (3/8�) - P/N N/A 4442842

For a more general look at the 2.2 and 2.2 turbo, click here (TBI) or here (turbo)

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