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Quad4 Technical Documents

Quad4 / Twincam Technical Data

Quad4/Twin Cam Faqs gathered from other websites for a list of those websites please go to the bottom of the page. Also this page will take a few seconds to load if your on dial up...... Thanks

2.4 LD9 Twin Cam Engine

Dyno Chart of base 2.4 LD9

Views Of 2.4 LD9 Engine
Intake/Exhaust Assembly Head Assembly Block Assembly Oil System Assembly Timing Assembly
Ignition Coil and Ignition Control Module (ICM) View
Left Side View of Engine Left Side Rear View of Engine

Fuel Shut Off: 6500 rpm
                Block: Cast Iron
            Cylinder Head: Cast Aluminum
Intake Manifold: Composite
Exhaust Manifold: High Silicon Molybdenum Cast Nodular Iron
         Main Bearing Caps: Cast Nodular Iron
Crankshaft: Cast Nodular Iron
Camshaft: Cast Iron

Engine Mechanical Specifications

Application	Metric	English
General Data
Engine Type	Inline 4 Cylinder
Displacement	2.4 Liter (146 CID)
Liter (VIN)	T
RPO	LD9
Bore	90 mm	3.54 in
Stroke	94 mm	3.70 in
Compression Ratio	9.5 to 1
Firing Order	1-3-4-2
Lubrication System
Oil Capacity Without Filter Change	3-3/4 Liters	4 qts
When Changing the Oil Filter, Up to an Additional 0.946 Liter or One Quart of Oil may be Needed. Filter Type or Equivalent	PF-44
Oil Pressure @ 3000 RPM	207 kPa	30 psi min.
Oil Pressure @ 900 RPM	69 kPa	10 psi min.
Cylinder Block
Cylinder Bore Diameter	89.994-90.006 mm	3.5110-3.5435 in
Out Of Round Maximum	0.010 mm	0.0004 in
Taper Maximum. Top to 106 mm (4.173 in) Down	0.008 mm	0.0003 in
Runout Rear Face of Block to the Crankshaft. Center Line Maximum	0.07 mm	0.002 in
Cylinder Head
Cylinder Head Flatness Maximum material that can be removed	0.076 mm	0.003 in
Do Not Resurface if the Measurement is Less Than	0.076 mm	0.003 in
Resurface	0.076-0.25 mm	0.003-0.010 in
Replace the Head if the Measurement is More Than	0.25 mm	0.010 in
Volume	58.9 cc-60.1 cc	1.5825 oz-1.6501 oz
Runout	0.05 mm	0.00196 in
Valve Seat Diameter Intake	34.066 mm	1.3412 in
Exhaust	27.048 mm	1.1436 in
Intake Valve Guide I.D.	5.921-5.941 mm	0.2331-0.2339 in
Exhaust Valve Guide I.D.	5.908-5.928 mm	0.2326-0.2334 in
Valve Stem to the Valve Guide Clearance Intake	0.024-0.070 mm	0.000986-0.00275 in
Exhaust	0.037-0.082 mm	0.00150-0.00320 in
Piston
Clearance in the Bore	0.019-0.051 mm	0.0007-0.0020 in
Compression Height	29.27-30.03 mm	1.180-1.182 in
Piston Diameter at 70°F (21°C)	89.957-89.973 mm	3.6203-3.6210 in
Piston Pin Bore I.D. at 70°F (21°C)	22.002-22.006 mm	0.8662-0.8664 in
Weight Less Pin and Rings	345 g +/- 6 g	12.075 oz +/- 0.1764 oz
Ring Groove Width, Top Compression	1.23-1.25 mm	0.048-0.049 in
Ring Groove Width, Second Compression	1.52-1.54 mm	0.0598-0.0606 in
Ring Groove Width, Oil	3.01-3.03 mm	0.1185-0.1193 in
Piston Rings
Compression Ring Width, Both	1.170-1.190 mm	0.0461-0.0469 in
Compression Ring Gap, Top	0.15-0.30 mm	0.006-0.012 in
Compression Ring Gap, 2nd Ring	0.30-0.41 mm	0.0119-0.0161 in
Oil Rails	0.025-0.65 mm	0.0098-0.0256 in
Compression Ring Side Clearance in the Groove, Top Ring	0.040-0.080 mm	0.0016-0.0031 in
Second Ring	0.030-0.070 mm	0.0012-0.0028 in
Oil Ring Width	0.497-0.523 mm	0.01957-0.02060 in
Oil Ring Gap	0.399-1.40 mm	0.0157-0.0551 in
Piston Pin
Diameter	21.995-22.000 mm	0.8659-0.8661 in
Pin to Piston Clearance Loose @ 21°C (70°F)	0.002-0.011 mm	0.00007-0.00043 in
Pin to Rod Clearance	0.007-0.032 mm	0.00027-0.0013 in
Weight	109 g	4.0207 oz
End Play on Floating Pin	0.0-0.6 mm	0.00-0.0236 in
Crankshaft and Connecting Rod
Main Bearing Journal Diameter	60.031-60.010 mm	2.3634-2.3626 in
Width, Main Thrust Bearing Journal No. 3, Including Fillets	27.837-27.913 mm	1.0959-1.0989 in
Out of Round Maximum	0.005 mm	0.0002 in
Straightness, Taper	0.007 mm	0.0003 in
Clearance	0.013-0.075 mm	0.0005-0.0030 in
Main Bearing Inside Diameter	60.033-60.071 mm	2.3635-2.3650 in
Crankshaft End Play	0.087-0.243 mm	0.0034-0.0095 in
Rod Bearing Journal Diameter	47.975-48.00 mm	1.8887-1.8897 in
Rod Bearing Inside Diameter	48.013-48.028 mm	1.8903-1.8909 in
Out of Round	0.005 mm	0.0002 in
Straightness, Taper	0.005 mm	0.0002 in
Clearance	0.013-0.053 mm	0.0005-0.0020 in
Rod Side Clearance	0.150-0.450 mm	0.0059-0.0177 in
Width	23.270-23.420 mm	0.9161-0.9220 in
Runout of Crankshaft at the Flywheel Flange Maximum	0.03 mm	0.001 in
Runout of Crankshaft Maximum	0.025 mm	0.00098 in
Supported on Front and Rear Journals Clearance to the Crankshaft Position Sensor	0.77-1.77 mm	0.0303-0.0697 in
Connecting Rod I.D. at the Small End	22.007-22.027 mm	0.8664-0.8672 in
Connecting Rod I.D. at the Large End	51.167-51.193 mm	2.0144-2.0154 in
Connecting Rod Width at the Small End	23.170-23.220 mm	0.9122-0.9142 in
Connecting Rod Width at the Large End	23.170-23.220 mm	0.9122-0.9142 in
Connecting Rod Width at the Large End in the Same Engine, All Within	2 g	0.0705 oz
Connecting Rod Clearance to Piston P	0.007-0.031 mm	0.00027-0.0122 in
Rod Assembly Center to Center Distance	142.450-142.550 mm	5.6125-5.6164 in
Flywheel Fit	0.000-0.013 mm loose	0.0000-0.0005 in
Flange Runout Maximum	0.03 mm	0.00120 in
Stroke of Crank	94 mm	3.70 in
A.D. of Seal Diameter on Crank	81.96-82.04 mm	3.2210-3.2299 in
Runout of Seal Surface	0.05 mm max	0.002 in
Balancer Hub I.D. to Crank Snout O.D. Crank	33.00-33.03 mm	1.2992-1.3004 in
I.D. Balancer	33.00-33.03 mm	1.2992-1.3004 in
Timing Gear Fit to Crankshaft Snout	33.03-33.06 mm	1.3004-1.3016 in
Camshaft
Lobe Lift Intake	9.0 mm	0.354 in
Exhaust	8.8 mm	0.346 in
Journal Diameter No. 1	39.93-39.95 mm	1.5720-1.5728 in
Journal Diameter No. 2-5	34.93-34.95 mm	1.3751-1.3760 in
Camshaft Bearing I.D. No. 1	40.00-40.040 mm	1.5748-1.5764 in
Camshaft Bearing I.D. No. 2-5	35.00-35.040 mm	1.3780-1.3795 in
Journal Clearance	0.050-0.110 mm	0.0019-0.0043 in
End Play Clearance	0.025-0.225 mm	0.0009-0.0088 in
Lobe Taper	0.046-0.083 mm	0.0018-0.0033 in
On diameter in	14.0 mm	0.5512 in
Camshaft Housing
Lifter Bore I.D.	33.989-34.019 mm	1.3381-1.3393 in
Lifter O.D.	33.959-33.975 mm	1.3369-1.3375 in
Lifter to Bore Clearance	0.016-0.058 mm	0.0006-0.0023 in
Lip Seal Bore I.D.	49.975-50.025 mm	1.9675-1.9695 in
Lip Seal O.D.	49.975-50.025 mm	1.9675-1.9695 in
Cam Carrier Flatness	0.07 mm	0.0028 in
Bottom Maximum Within 100.0 mm (3.937 in)	0.025 mm	0.001 in
Valve Lifter
Clearance in Bore	0.016-0.058 mm	0.0006-0.0023 in
Valves
Valve Installed Height, All	24.86-25.62 mm	0.9787-1.0024 in
Valve Tip Above Spring Retainer, All	0.602-0.820 mm	0.0237-0.0323 in
Intake Valves, Valve Face Angle	46 degrees
Valve Seat Angle	45 degrees
Head Diameter	35.5 +/- 0.03 mm	1.3987 +/- 0.0011 in
Stem Diameter	5.921-5.941 mm	0.2331-0.2339 in
Overall Length	107.290 mm	4.2272 in
Stem To Guide Clearance	0.025-0.069 mm	0.0009-0.0025 in
Valve Seat Width	0.94-1.90 mm	0.0370-0.0748 in
Valve Seat Margin Minimum	0.25 mm	0.0098 in
Valve Face Runout	0.038 mm	0.0015 in
Valve Tip to the Groove Centerline	3.420 mm	0.1346 in
Exhaust Valves, Valve Face Angle	45.5 degrees
Valve Seat Angle	45 degrees
Head Diameter	28.870-29.130 mm	1.1366-1.1469 in
Stem Diameter	5.908-5.928 mm	0.2326-0.2334 in
Overall Length	108.17 mm	4.2586 in
Stem to Guide Clearance	0.038-0.082 mm	0.0016-0.0032 in
Valve Seat Width	0.094-1.90 mm	0.0037-0.0748 in
Valve Seat Margin Minimum	0.25 mm	0.0098 in
Valve Face Runout	0.038 mm	0.0015 in
Valve Tip to Groove Centerline	3.420 mm	0.1346 in
Valve Springs
Valve Spring Pressure Load @ 36.5 mm (1.4370), Closed	223-247 N	50-55 lb
Load @ 26.98 mm (1.0622 in), Open	544-596 N	122-133 lb
Balance Shafts
Housing Flatness Maximum	0.076 mm	0.0030 in
Bore Roundness	0.025 mm	0.0009 in
Bearing Thickness	1.500-1.508 mm	0.0590-0.0593 in
Bearing I.D.	30.019-30.061 mm	1.1819-1.1835 in
Housing Bore	33.025-33.050 mm	1.3001-1.1801 in
Shaft Journal O.D.	29.950-29.975 mm	1.1791-1.1801 in
Journal Taper (Intentional Towards Counterweight	0.000-0.010 mm	0.000-0.0004 in
Journal Roundness Maximum	0.005 mm	0.0002 in
Bearing Clearance	0.044-0.111 mm	0.0017-0.0044 in
Gear Diameter over 2.5 mm pins	61.050-61.145 mm	2.4035-2.4073 in
Gear Backlash	0.008-0.086 mm	0.0003-0.0034 in
Chain Slack, With 6 lb of pressure applied to the guide	1.0 mm	0.040 in
Shaft Groove Width	3.23-3.40 mm	0.127-0.134 in
Thrust Plate Thickness	2.945-3.045 mm	0.1159-0.1199 in
Endplay	0.185-0.455 mm	0.0073-0.0179 in
Oil Pump
Gerotor Pocket Depth	17.11-17.16 mm	0.6736-0.6756 in
Diameter	54.033-54.083 mm	2.1273-2.1292 in
Inner Gerotor Tip Clearance Maximum	0.15 mm	0.0059 in
Outer Gerotor Diameter Clearance	0.033-0.133 mm	0.0013-0.0052 in
Outer Gerotor Thickness	17.087-17.099 mm	0.6727-0.6731 in
Oil Pump Drive to the Driven Gear Backlash	0.23-0.51 mm	0.0091-0.0201 in

Fastener Tightening Specifications

Application	Specifications
Application	Metric	English
Balance Shaft Cover Nut and Bolt	13 N·m	115 lb in
Balance Shaft Driven Sprocket Bolt (left hand thread)	40 N·m + 45°	30 lb ft + 45°
Balance Shaft Housing Bolts 8 mm hex	10 N·m + 40°	89 lb in + 40°
Balance Shaft Housing Bolts 10 mm hex	15 N·m + 40°	11 lb ft + 40°
Balance Shaft to block Bolts 13 mm hex	25 N·m + 70°	18 lb ft + 70°
Balance Shaft to block Bolts 15 mm hex	53 N·m	39 lb ft
Balance Shaft to Block Bolts 18 mm hex	40 N·m + 60°	30 lb ft + 60°
Camshaft (exhaust) Rear Cover	14 N·m	124 lb in
Camshaft Position Sensor Bolt	10 N·m	89 lb in
Camshaft Sprocket to the Camshaft Bolt	70 N·m	52 lb ft
Connecting Rod Nuts	25 N·m + 80°	18 lb ft + 80°
Coolant Bleeder Valve	Fully Driven, Seated , Not Stripped
Coolant Outlet to Cylinder Head	26 N·m	19 lb ft
Coolant Pump Cover to the Block	26 N·m	19 lb ft
Coolant Pump to the Coolant Pump Cover	14 N·m	124 lb in
Coolant Pump to the Timing Chain Housing	26 N·m	19 lb ft
Crankshaft Balancer to the Crankshaft	175 N·m + 90°	129 lb ft + 90°
Crankshaft Bearing Cap Bolts	20 N·m + 90°	15 lb ft + 90°
Crankshaft Position Sensor to Block	9 N·m	80 lb in
Cylinder Head Bolts	Refer to Procedure
Cylinder Head Threaded Plug	26 N·m	19 lb ft
EGR Pipe to the EGR Adapter	26 N·m	19 lb ft
Engine Coolant Air Bleed Pipe	14 N·m	124 lb in
Engine Coolant Air Bleed Pipe Nut	42 N·m	31 lb ft
Engine Coolant Temperature Gauge Sensor to the Cylinder Head	Fully Driven, Seated, Not Stripped
Engine Coolant Temperature Sensor to the Coolant Outlet	11 N·m	97 lb in
Engine Lift Bracket	96 N·m	68 lb ft
Engine Mount Bracket Adapter to Block Bolt Auto Trans	60 N·m + 60°	44 lb ft + 60°
Engine Mount Bracket Adapter to Block Bolt Manual Trans	60 N·m + 60°	44 lb ft + 60°
Engine Mount (right hand side) to the Body Support Bolt	66 N·m	49 lb ft
Engine Mount (right hand side) to the Body Support Nut	44 N·m	32 lb ft
Engine Mount (right hand side) to the Engine Mount Bracket Bolts	62 N·m	46 lb ft
Engine Mount Strut	100 N·m	74 lb ft
Engine Mount Strut Bracket Bottom Bolts	130 N·m	96 lb ft
Engine Mount Strut Bracket Front Bolts	66 N·m	49 lb ft
EVAP Canister Purge Valve Solenoid Bracket Bolt	8 N·m	72 lb in
Exhaust Manifold Brace to the Exhaust Manifold Bolt	56 N·m	41 lb ft
Exhaust Manifold Brace to the Oil Pan Nuts	26 N·m	19 lb ft
Exhaust Manifold to the Cylinder Head Nuts	15 N·m	11 lb ft
Exhaust Manifold to the Cylinder Head Studs	11 N·m	97 lb in
Exhaust Manifold Upper Heat Shield to the Manifold Bolts	14 N·m	124 lb in
Flywheel to Clutch Cover	20 N·m + 45°	15 lb ft + 45°
Flywheel to the Converter	66 N·m	49 lb ft
Flywheel to the Crankshaft	30 N·m + 45°	22 lb ft + 45°
Front Cover to the Timing Chain Housing	12 N·m	106 lb in
Fuel Pipe Bracket to the Camshaft Housing	15 N·m	11 lb ft +30°
Fuel Pipe to the Fuel Rail Nut	30 N·m	22 lb ft
Fuel Rail to the Camshaft Housing	26 N·m	19 lb ft
Ignition Coil and Module Assembly to the Camshaft Housings	22 N·m	16 lb ft
Intake Manifold to the Cylinder Head Bolts/Nuts	24 N·m	18 lb ft
Intake Manifold to the Cylinder Head Studs	11 N·m	97 lb in
Knock Sensor	20 N·m	15 lb ft
Oil/Air Separator To Block Bolts	24 N·m	18 lb ft
Oil Dipstick Tube Bolt/Screw	8 N·m	71 lb in
Oil Filter Connector to the Block	29 N·m	21 lb ft
Oil Filter to the Block	3/4 to one complete turn after gasket contact
Oil Pan Bolts	24 N·m	18 lb ft
Oil Pan Bolts, Second Set	12 N·m	106 lb in
Oil Pan Drain Plug	26 N·m	19 lb ft
Oil Pan Studs	26 N·m	19 lb ft
Oil Passage Plug Bolt	30 N·m	22 lb ft
Oil Passage Plugs, 1/4x18	20 N·m	15 lb ft
Oil Passage Plugs, 3/8x18	30 N·m	22 lb ft
Oil Passage Plugs, Block 1/8x27	10 N·m	89 lb in
Oil Pressure Switch	14 N·m	124 lb in
Oil Pump Cover to the Oil Pump Housing - Short Bolt	10 N·m	89 lb in
Oil Pump to the Balance Shaft Housing - Long Bolts	12 N·m	106 lb in
Oxygen Sensor To Exhaust Manifold	42 N·m	31 lb ft
Powersteering Pipe to the Pump Nut	27 N·m	20 lb ft
Powersteering Pump to the Cam Carrier Bolts	26 N·m	19 lb ft
Rear Crankshaft Seal Housing to Block	12 N·m	106 lb in
Spark Plugs to the Cylinder Head	18 N·m	13 lb ft
Starter to the Block Bolt	90 N·m	66 lb ft
Tensioner to Tensioner Bracket Nut	54 N·m	40 lb ft
Throttle Body to the Intake Manifold	10 N·m	89 lb in
Thrust Plate to the Balance Shaft Housing	13 N·m	115 lb in
Timing Chain Housing to the Block Bolts/Studs	29 N·m	21 lb ft
Timing Chain Housing to the Camshaft Housings	26 N·m	19 lb ft
Timing Chain Tensioner to Housing and Block	10 N·m	89 lb in
Transaxle To Block Bolt	58 N·m	43 lb ft
Transaxle To Block Nut	66 N·m	49 lb ft
Transaxle To Block Stud	13 N·m	115 lb in

GM SPO Group Numbers

Application	GM SPO Group Number
Connecting Rod	0.603
Connecting Rod Bearing Kit	0.616
Crankshaft	0.646
Crankshaft Balancer Kit	0.659
Cylinder Head	0.269
Cylinder Head Gasket Kit	0.289
Drive Belt Tensioner	1.060
Engine Cooling Thermostat	1.246
Engine Front Cover	0.206
Engine Front Cover Gasket	0.207
Exhaust Camshaft	0.519
Exhaust Manifold	3.601
Exhaust Manifold Gasket	3.270
Flywheel Housing Cover	0.679
Flywheel Kit	0.666
Intake Camshaft	0.519
Intake Manifold	3.265
Intake Manifold Gasket	3.270
Oil Level Indicator	1.516
Oil Pan	1.426
Piston with Pin	0.629
Power Steering Pump Kit	6.605
Power Steering Pump Gasket	6.606
Spark Plug	2.270
Throttle Body	3.335
Throttle Body Gasket	3.336
Water Pump	1.069
Water Pump Cover	1.073

Sealers, Adhesives, and Lubricants

Application	Type of Material	GM Part Number
Balance Shaft Housing to Block Bolts	Thread Locker	12345493
Cam Carrier Oil Cup Plugs	Sealant	12346004
Cam Carrier Oil Passage Plug	Sealant	12345382
Camshaft Lobes and Journals	Camshaft and Lifter Prelube	12345501
Camshaft Sprocket Bolts	Thread Locker	12345493
Chain Housing to Cam Housing Bolts	Thread Locker	12345382
Coolant Air Bleed Pipe O-rings	Coolant	--
Coolant Outlet O-rings	Coolant	--
Coolant Temperature Sensor	Thread Locker	12346004
Cooling System	Coolant Sealant Pellets	3634621
Crankshaft Main Bearing Bolts	Engine Oil	--
Crankshaft Rear Main Seal	Engine Oil	--
Cylinder Block Drain Plug	Sealant	12345382
Cylinder Block Oil Feed Plug	Sealant	12345382
Cylinder Head Bolts	Engine Oil	--
Cylinder Head Coolant Plugs	Sealant	12345382
Flywheel to Crankshaft Bolts	Thread Locker	12345493
Front Main Oil Passage Plug	Sealant	12345382
Front Oil Seal	Chassis Grease	01051344
Heater H20 Control Assembly Valve	Thread Locker	12346004
Injector O-rings	Engine Oil	--
Lifters	Camshaft and Lifter Prelube	12345501
Lifters -- Store submerged	Engine Oil	--
Main Oil Passage Plug	Sealant	12345382
Manifold Air Temperature Sensor	Thread Locker	12346004
New Camshaft	Engine Oil Supplement	01052367
New Lifters	Engine Oil Supplement	01052367
Oil Filter and Rear Oil Passage Plugs	Sealant	12345382
Oil Filter Plug	Sealant	12345382
Oil Level Sensor	Thread Locker	12345382
Pistons	Varnish Remover	12345368
Power Steering Pump to Cam Housing Seal	Sealant	12346286
Valves	Varnish Remover	12345368
Water Outlet Valve	Thread Locker	12346004

2.3 Quad 4 Engine

Specifications for 1993 2.3L (VIN A) Quad4 Engine

Displacement: 2.3 Liters (138 cid)
Type: DOHC with naturally aspirated port fuel injection.
Horsepower: 155 on average (SO) 180 (HO)
Torque: 155 ft-lbs on average (SO) 165 (HO)
Ignition: Integrated Direct Ignition

Engine Specifications	English (in)	Metric (mm)
Type	Inline 4
Displacement	138 CI
Liter (VIN)	2.3 (A)
RPO	LGO
Bore	3.62	92
Stroke	3.35	85
Compression Ratio	10:1
Firing Order	1-3-4-2
Oil Capacity	4 Qts.
Filter Type	PF-1225 (AC #)
Oil Pressure @ Operating Temperature
2000 RPM	30 PSI	207 kPa
900 RPM	15 PSI	103 kPa
Oil Pump
Gerotor Pocket
Depth	0.6736-0.6756	17.11-17.16
Diameter	2.1273-2.1292	54.033-54.083
Inner Gerotor Tip Clearance -Max.	0.0059	0.15
Outer Gerotor Diameter Clearance	0.0013-0.0052	0.033-0.133
Outer Gerotor Thickness	0.6727-0.6731	17.087-17.099
Oil Pump Drive to Driven Gear Backlash	0.0091-0.0201	0.23-0.51
Bore Diameter	3.6217-3.6223	91.992-92.008
Bore Out of Round Max	0.0004	0.010
Bore Taper Max Top to 106mm (4.173 in) down	0.0003	0.008
Runout - Rear Face of Block to Crank Ctr Line Max	0.002	0.05
Cylinder Head
Flatness - Max	0.008	0.203
Volume	1.5825-1.6501 (oz.)	46.8-48.8 (cc)
Runout	0.00196	0.05
Diameter
Intake	1.3412	35.066
Exhaust	1.1436	29.048
Valve Guide I.D.	0.2762-0.2772	7.015-7.041
Valve Stem to Valve Guide Clearance
Intake	0.000984-0.00271	0.025-0.069
Exhaust	0.00149-0.00319	0.038-0.081
Piston
Clearance in Bore	0.0007-0.0020	0.019-0.051
Compression Height	1.260 +/- 0.004	32.0 +/- 0.1
Diameter @ 70 Degrees F. (21 C)	3.6203-3.6210	91.957-91.973
Pin Bore I.D. @ 70 degrees F (21 C)	0.8664-0.8666	22.008-22.012
Weight Less Pin & Rings	14.8151 +/- 0.0021 oz	420 +/- 6 g
Ring Groove Width - Top Compression	0.061-0.062	1.55-1.57
Ring Groove Width - Second Compression	0.0598-0.0606	1.52-1.54
Ring Groove Width - Oil	0.1182-0.1193	3.01-3.03
Piston Rings
Compression Ring Width (both)	0.05708-0.05827	1.450-1.480
Compression Ring Gap (top)	0.0138-0.0236	0.35-0.60
Compression Ring Gap (2nd)	0.0157-0.0256	0.40-0.65
Compression Ring Side Clearance in Groove
Top Ring	0.0027-0.0047	0.070-0.120
2nd Ring	0.00157-0.00315	0.040-0.080
Oil Ring Width	0.01657-0.02060	0.497-0.523
Oil Ring Gap	0.0157-0.0551	0.40-1.40
Piston Pin
Diameter	0.8659-0.8661	21.995-22.000
Pin to Piston Clearance, Loose @ 70 degrees F (21 C)	0.00031-0.00066	0.008-0.017
Pin to Rod Clearance	0.00027-0.00122	0.007-0.031
Weight	4.0207 oz	114 g
End Play on Floating Pin	0.00-0.0236	0.0-0.6
Main Bearing Journal
Diameter	2.0470-2.0480	51.996-52.020
Width-Main, Thrust Bearing Journal #3 Including Fillets	1.0959-1.0989	27.837-27.913
Out of round - Max	0.0005	0.0127
Taper	0.0005	0.0127
Clearance	0.0005-0.0023	0.013-0.058
Crankshaft End Play	0.0034-0.0095	0.087-0.243
Rod Bearing Journal
Diameter	1.8887-1.8897	47.957-48.00
Out of Round - Max	0.0005	0.0127
Taper	0.0005	0.0127
Clearance	0.0005-0.0020	0.013-0.053
Rod Side Clearance	0.0059-0.0177	0.150-0.450
Width	1.0925-1.1024	27.75-28.00
Runout of Crank at Flywheel Flange - Max	0.00098	0.025
Supported on Front and Rear Journals	0.00098	0.025
Clearance to Crankshaft Position Sensor	0.0303-0.0697	0.77-1.77
Connecting Rod I.D. - Small End	0.8664-0.8672	22.007-22.027
Connecting Rod I.D. - Large End	2.0144-2.0154	51.167-51.193
Connecting Rod Width - Small End	0.8622-0.8700	21.900-22.100
Connecting Rod Width - Large End	1.0846-1.0866	27.550-27.600
Connecting Rod Weight Large End (in same Engine) All Within	0.0705 oz	2 g
Connecting Rod Clearance to Piston Pin	0.00027-0.0122	0.007-0.031
Rod Assembly Ctr to Ctr Distance	5.8051-5.8090	147.450-147-550
Oil Pump Drive
Oil Pump Drive Gear	3.2621-3.2632	82.859-82.887
Crankshaft O.D.	3.2681-3.2672	83.012-82.988
Oil Pump Drive Gear to Crankshaft	0.00333-0.00601	0.101-0.153
Flywheel
Fit	0.00000-0.0005	0.000-0.013
Flange Runout - Max	0.00120	0.03
Stroke of Crank	3.3366-3.3504	84.9-85.10
O.D. of Seal Diameter on Crank	3.2210-3.2299	81.96-82.04
Runout of Seal Surface	0.0012	0.03
Balancer Hub I.D. to Crank Snout
O.D. Crank	1.2992-1.3004	33.00-33.03
I.D. Balancer	1.2992-1.3004	33.00-33.03
Timing Gear Fit to Crankshaft Snout	1.3004-1.3016	33.03-33.06

Fastener Tightening	English (ft-lbs)	Metric (Nm)
Camshaft Housing and Cover to Cylinder Head - Plus Rotate (82A)	11 + 90 degrees	15 + 90 degrees
Camshaft (Exhaust) Rear Cover (96)	10	14
Camshaft Sprocket to Cam Bolt (73)	52	70
Connecting Rod Nuts - Plus Rotate (43)	18 + 80 degrees	25 + 80 degrees
Coolant Outlet to Cylinder Head	19	26
Coolant Pump to Timing Chain Housing	19	26
Coolant Pump to Coolant Pump Cover	124	14
Coolant Pump Cover to Block	19	26
Crankshaft Balancer to Crankshaft - Plus Rotate (63)	110 + 90 degrees	150 + 90 degrees
Crankshaft Bearing Cap Bolts - Plus Rotate (40)	15 + 90 degrees	20 + 90 degrees
Crankshaft Position Sensor to Block (323)	80 (in-lbs)	9
Cylinder Head Bolts	Refer to Figure 42
Cylinder Head Threaded Plug (94)	40	54
Engine Mount Bracket to Engine Mount Bolts	40	54
Engine Mounts	Refer to Figures 11 - 12
ESC Knock Sensor	15	20
Exhaust Manifold:
Upper Heat Shield to Manifold Nuts (316)	19	26
Manifold to Cylinder Head Nuts (160)	31	42
Manifold to Cylinder Head Studs (110)	106 (in-lbs)	12
Manifold Brace to Exhaust Manifold	40	54
Manifold to Oil Pan Nuts (185)	19	26
Manifold Lower Head Shield Bolt (318)	124 (in-lbs)	14
Manifold Lower Heat Shield Stud (319)	63	86
Manifold Lower Heat Shield Stud (317)	19	26
Manifold Studs to Manifold	19	26
Exhaust Pipe to Exhaust Manifold Nust (418)	19	26
Flywheel to Clutch Cover	22	30
Flywheel to Crankshft - Plus Rotate (20)	22 + 45 degrees	30 + 45 degrees
Front Cover to Timing Chain Housing (60, 64)	106 (in-lbs)	12
Fuel Pipe Bracket to Camshsft Housing - Plus Rotate (82b)	11 + 25 degrees	15 + 25 degrees
Fuel Rail to Camfhsft Housing (303)	19	26
Generator, Compressor and Tensioner Bracket Assembly - Bracket to Block (148)	40	54
Generator, Compressor and Tensioner Bracket Assembly - Bracket to Idler (157)	40	54
Generator, Compressor and Tensioner Bracket Assembly - Bracket to Front Brace (149, 150)	19	26
Generator, Compressor and Tensioner Bracket Assembly - Rear Brace to Blocker to Idler (153)	40	54
Ignition Coil & Module Assembly to Camshaft Housings (80)	16	22
Intake Manifold:
Manifold Brace Bolts	19	26
Manifold to Cylinder Head (102, 104, 105)	18	25
Manifold to Cylinder Head Studs	97 (in-lbs)	11
Oil/Air Separator to Intake Manifold (323)	71 (in-lbs)	8
Oil Filter Connector to Block (15)	21 (in-lbs)	29
Oil FIll Tube Bolt/Screw	71 (in-lbs)	8
Oil Filter to Block (16)	3/4 - 1 Turn after seat
Oil Pan Baffle Bolts (36)	30	40
Oil Pan Baffle Studs (32)	30	40
Oil Pan Bolts (39b)	18	24
Oil Pan Bolts (39a, 39c)	106 (in-lbs)	12
Oil Pan Drain Plug	19	26
Oil Pan Studs (39d)	19	26
Oil Passage Plugs, Block - 1/8 x 27	88 (in-lbs)	10
Oil Passage Plugs, 3/8 x 18	22	30
Oil Passage Plugs, 1/4 x 18	24	32
Oil Passage Plug Bolt (4d)	22	30
Oil Pump to Block	40	54
Oil Pump Brace to Oil Pan Baffle Stud Nut (34)	19	26
Oil Pump Cover to Oil Pump Body	106 (in-lbs)	12
Oil Pump Gerotor Cover to Oil Pump Body	106 (in-lbs)	12
Oil Pump Screen to Brace (30)	106 (in-lbs)	12
Oil Pump Screen to Pump (31)	30	40
Rear Crankshaft Seal Housing to Block (22)	106 (in-lbs)	12
Spark Plugs to Cylinder Head (92)	16	22
Starter to Block Bolt	71	96
Starter to Transaxle Bolt	71	96
Timing Chain Housing to Block or Camshaft Housings (48, 49)	19	26
Timing Chain Housing to Block Stud (50)	19	26
Timing Chain Tensioner to Housing & Block (74)	89 (in-lbs)	10
Throttle Body to Intake Manifold	19	26
Transaxle to Block Bolt (187)	40	54
Transaxle to Block Nut (188)	41	56
Transaxle to Block Stud (189)	115 (in-lbs)	13

2.3 intake manifold 'How To' Modification and Install Guide

2.3 HO Intake Modified to use on the 2.4 (Mantapart's Design)

This is one way to do it... Or you can go to http://www.mantapart.com and buy a log intake that's direct fit and made for the 2.4L. Depends on how much you like to work on your car.

Parts to buy before hand
2.3 Intake Mainfold
2.3 intake gasket kit....... small tube of RTV (silicone sealer)

Removal of stock parts
Disconnect the negative cable on the battery. Unplug all sensors and vacuum lines on the intake and t/b. Remove the throttle cables and bracket from the t/b. Remove the 4 t/b bolts and t/b and 7 intake manifold bolts and manifold. Remove the black tube that goes to your brake booster. You will be cutting this tube later. On the front of your trans, you will find a grounding stud, with wires and a nut on it. You will need to remove this, and relocate it down to the bolt below (I found this to be in the way on the 5 speeds, not sure on the auto). If you have a 96-99 (mid 99 they stopped using the egr) you will have to remove your EGR and the mounting bracket. You will then need to install a exhaust gasket from a 99+ w/o EGR, in place of your exhaust manifold gasket, or make a block off plate for the front of your engine. Plug the wires back into the EGR, and zip tie it to the power steering lines just to the right of the engine.

2.3 Intake
First things first, find yourself a good intake. The Log style is a good choice, and make sure its off a DOHC engine. There are a few part #'s for the H.O. ones, I have a few of the #'s: 22538691, 24570288, 24571319.

Modifying the intake. I used an extra 2.4 head to mark off the ports, but since most of you wont have this, you will need to use your 2.4 intake gasket. Its not easy, but you can mask of the parts you need to remove. Once you have the intake matched to the head, you now need to modify 4 bolt holes. The outer 2 and the center 1 line right up, its the 2 'Pairs' of bolt holes on either side of center that need to be modified. The bottom 2 need to be slotted out, the inner 2 need to be drilled lower, you will notice/see how far, once you try to line up the intake to the head. At this time, you should make sure you have a 2.3 intake gasket kit, and modify it to match your newly modified manifold. THOROUGHLY CLEAN THE INTAKE, REMOVE ALL METAL SHAVINGS!!!

Installing the intake..... Try to test fit the intake on the head, w/o a gasket for the moment. Make sure it fits, and nothing is in the way. If all is ok, remove the intake, install the gasket with a SMALL amount of silicone sealer, and reinstall the intake.

Throttle Body
Now for a t/b. You can use either a 2.3 56mm t/b, or a 2.4 t/b, either the stock 52mm, the Mantapart 56mm, the RSM 59mm or 62mm.

If you go with the 2.3 t/b, get a 93+ one, either with or with out the cruise option. Remove all the sensors, and be careful with the bolts, since they are weak, and might break. You can use your 2.4 Idle Air Control sensor, just pull off the plunger on the 2.3 one, and swap it with the 2.4 one. For your Throttle Position Sensor, you need to use your 2.4 one, check your position of it on the 2.4, and place it on your 2.3 t/b. You will need to cut one of the mounting ears off, and drill a new hole in the t/b for the other one. Tap the hole, and mount the sensor.

If you go with the 2.4 t/b, you don't need to mess with any sensors, use your stock ones. You will need to drill out the 2 holes that match up with the holes in the intake. Just select a drill bit that is slightly larger then the bolts. To mount the throttle cable bracket, I would first get one off a '95 2.3(part # 22590179. This part is now discontinued by GM), just because it was made to fit in the J-body with this intake manifold. The upper bolt hole in the t/b will need to be taped, to bolt the upper part of the bracket in place.

Either way you will need a 2.3 intake gasket kit from any parts store, in the kit you should get a t/b gasket. Use a SMALL amount of silicone sealer, and mount the t/b gasket and t/b to the intake.

Rewiring and plumbing Vacuum lines
You will have to remove some electrical tap, and open the loom slightly. You SHOULD NOT NEED TO CUT ANY WIRES!!! Run your Cam Position sensor plug behind your intake, between the runners, and plug it in. Pull the rest of the wires to the t/b. Plug in your IAC and TPS. I mounted the MAP sensor onto the intake by the power steering pump. I ran the vacuum for it to the port on the back side of the intake. The vacuum line for the FPR goes to the first port on the left of the intake. There is a vacuum line that comes up from underneath (just behind the A/C compressor) rout that one to the center vacuum port. The large hole in the front can be plugged with a common pipe plug found at a hardware store. There should be one small vacuum line and the large tube from the brake booster left. The small one is for you HVAC controls, mount that to your t/b. The black tube from the booster needs to be cut, you will need a piece long enough to reach the rubber hose that plugs right into the booster itself. Should be about 6-8" long. Remove the rubber elbow from the rest of the tube, and install it onto the large opening on the t/b. This leaves you 2 ports on the t/b that need to be plugged, you can pick up vacuum caps from a auto place, or just run a small piece of tube from one to the other. Now is the time to connect your throttle cables. Connect them the same way you took them off your t/b. If you have cruise, GM makes a part to turn your cruise box over.

EGR
We removed the egr and mounting bracket from the head, kept the egr plugged into the wire harness, and ran a vacuum line from the intake manifold (any port but FROM THE MAP SENSOR) to the large open port on the egr. We used a brass nipple fitting and a filtered air line fitting (3/8 pipe thread), and tapped the large egr port with a 3/8 NPT tap. No check engine light. Then just zip tie the egr out of harms way.

Intake and filter
You can use your stock 'S' tube with a cone filter to the stock location, or you can cut the tube, and run the filter straight down...... or make up your own combo.....

That is it, you should now be able to reconnect the negative cable, and start your baby up. At start up, it will Idle about 2000-3500 rpm, till the IAC valve resets.... if it goes any higher, or doesn't come down after 30 seconds. you have a vacuum leak. To check for a leak, listen for a whistle, or just shut it off, and check your gaskets. If everything is ok, let it idle for 5-10 minutes to let everything reset. If you get a SES light, take it into any AutoZone and get it checked. Make sure you get the code # and what it is.

_______________________________________________________________________________________________________________

*All Pictures here are for reference only. None of these pictures are original.
Original Directions taken from SpeedRacerZ

Even More Quad 4 Info

Cylinder Heads Of The 2.3 Quad 4

There has been 7 different head on the 2.3 Quad 4 from 87 to 97 DOHC and SOHC

		Intake Flow numbers CFM		Exhaust Flow numbers CFM
Part Number	Lift	Stock	Modified	Stock	Modified
25539086 1989-’92 VIN A (H.O.) and 1990-’92 VIN D – When the H.O. motor was introduced in late ’89, it had a new head with bigger valves, along with subtle revisions to the chamber and ports to "reduce restriction and improve flow.". The intake valves were increased from 35.5mm to 36.5mm and the exhausts went from 30.0mm to 31.5mm.	.050 .100 .200 .300 .400	43 100 182 242 280	39 89 172 239 285
22530955 1987-’89 VIN D – It had a "modified pent roof" design and siamesed ports for each chamber. The intake valves were 35.5mm and the exhaust valves were 30.0mm.	.100 .200 .300 .400 .500		96 172 218 239 241		71 132 163 173 175
24570753 1993 VIN A (H.O.) and 1993 VIN D – The ’93 DOHC engines came with a new head that had smaller exhaust ports and two larger 10.0mm studs for the exhaust manifold. The service replacement is a 24573303 casting.
24575456 1994-’95 VIN D – The head for the ’94 DOHC engine had the smaller exhaust ports and the modified hole for the water outlet, just like the one on the ’94 SOHC head.
24574683-18 1996-’98 VIN T – The new 2.4L engine came with a different head that had several changes. The chamber was shaped more like an oval with straight sides, both the intake and exhaust valves were smaller, both the intake and exhaust ports were different, and there was an EGR crossover passage cast into the head just below the water outlet.

________________________________________________________________________________________________________________
Taken From http://users.skynet.be/nvmygtz/ref.htm (Adam Mufford)

Exhaust
The Quad 4 and Twin cam motors like to breath so give them a nice open exhaust 2.5" is a real good one to go with.
Ron.S has made a nice system Click!

93-94 Cast Manifold
87-89 LO Tubular Manifold
87-89 LO Tubular Manifold (Modified)
89-92 HO Cast Manifold (Modified)	Adam's Ported Mantapart Manifold
89-92 HO Cast Manifold (Modified)	Rex's Self Ported Manifold
90-92 Stock Down-pipe
90-92 Stock Down-pipe
90-92 Modified Down-pipe	Adam's
90-92 Modified Down-pipe	Rex's

Intake
The Quad 4 and twin cam has had 4 types of intake manifolds
1.The first was a tubular manifold that had long individual runners. I looked a lot like a exhaust manifold.
2. The Log style intake has shorter brooder runners pointing down in to a larger chamber that is attached to the T/B.
3. The 93 and up uses the same type but has some kind of restriction that the 92 and earlier do not have. The T/B and linkage mount is also a different style.
4. The Twin cam uses a long all most equal length intake with the T/B sitting right on the top middle position. It is made of composite material.

Cast Alum. Tubular
HO Cast Alum. Log style

Throttle body
There are at lease 3 different t/b's.

Stock 89-92 w/coolant attachment

Cams
There has been 4 different cam housing on the Q4 from 87-95

They vary by:
    1.)The type of seal between the housings
    2.)The placement of the seal grove
    3.)The casting type (Sand and Die)
    4.)Lifter bore size on the 95+
    5.)And the SOHC

Type:	Lift	Duration @.050	Intake Part #	Exhaust Part #
W41	.410	.219
W41#2(hot cams)	.410	.241
Crane Compucam	.430	.222	Regrind00408	Regrind00409
Crower	.346	.224	E-7583	E-7583
HO(Vin A)	.410	.212	22545577	22545578
LD2 1987-89	.350	.212
LD2 1990-94	.375	.200
Genertec XX5	.360	.211	Extra lobes provided for the cam sensor (Auto tranny only) Hex Drive on intake cam for Power Steering
Genertec XX5	.360	.212
Twin Cam 1995 (Vin D)	.360
Twin Cam Intake 1996 (Vin T)	.354	198
Twin Cam Exhaust 1996 (Vin T)	.345/6	187
Crane Compucam and W41 cams

Head
There has been 7 different head on the Q4 from 87 to 97 DOHC and SOHC
Pictures of Modified heads Here!

		Intake Flow numbers CFM		Exhaust Flow numbers CFM
Part Number	Lift	Stock	Modified	Stock	Modified
25539086 1989-’92 VIN A (H.O.) and 1990-’92 VIN D – When the H.O. motor was introduced in late ’89, it had a new head with bigger valves, along with subtle revisions to the chamber and ports to "reduce restriction and improve flow.". The intake valves were increased from 35.5mm to 36.5mm and the exhausts went from 30.0mm to 31.5mm.	.050 .100 .200 .300 .400	43 100 182 242 280	39 89 172 239 285
22530955 1987-’89 VIN D – It had a "modified pent roof" design and siamesed ports for each chamber. The intake valves were 35.5mm and the exhaust valves were 30.0mm.	.100 .200 .300 .400 .500		96 172 218 239 241		71 132 163 173 175
24570753 1993 VIN A (H.O.) and 1993 VIN D – The ’93 DOHC engines came with a new head that had smaller exhaust ports and two larger 10.0mm studs for the exhaust manifold. The service replacement is a 24573303 casting.
24575456 1994-’95 VIN D – The head for the ’94 DOHC engine had the smaller exhaust ports and the modified hole for the water outlet, just like the one on the ’94 SOHC head.
24574683-18 1996-’98 VIN T – The new 2.4L engine came with a different head that had several changes. The chamber was shaped more like an oval with straight sides, both the intake and exhaust valves were smaller, both the intake and exhaust ports were different, and there was an EGR crossover passage cast into the head just below the water outlet.

Blocks
There has been 6 different blocks from 87-95, 4 different Ft covers, 3 different oil pumps

Cranks
Three different cranks have been in from 87-95

Rods
Three different rod designs have been in from 87-95

Fuel System
The stock W-41 and HO fuel injectors are 32Lbs/Hr.(336cc/Min.)
The LO are 28Lbs./Hr.
The stock fuel system will support up to a bought 230-240HP at the crank with a duty cycle of 80%
The stock fuel pressure is 42 PSI

Gaskets
The current GM replacement P/N is 12356550
Also Fel-Pro is the gasket of choice for many rebuilder, enthusiast.

Ignition
Also know as IDI Integrated Direct Ignition

Reading Material

Fueling Aerotech	Quad 4 Motor	GTZ	Other
Calais Speed Record 1	Clevite Add 1	Motor Trend Review 1	Rocketparts 1990
Calais Speed Record 2	Clevite Add 2	Motor Trend Review 2	Page 1
Calais Speed Record 3	GM Head Service	Motor Trend Review 3	Page 2
Calais Speed Record 4	Automotive Rebuilder	Motor Trend Review 4	Page 3
Calais Speed Record 5	Header Advice 1	Motor Trend Review 5	Page 4
Cutlass Supreme Speed Record 1	Header Advice 2		Page 5
Cutlass Supreme Speed Record 2	Header Advice 3		Page 6
Cutlass Supreme Speed Record 3	Header Advice 4		Page 7
Cutlass Supreme Speed Record 4	Header Advice 5		Page 8
Cutlass Supreme Speed Record 5	Super Street Page 1		Page 9
Cutlass Supreme Speed Record 6	Super Street Page 2		Page 10
	Super Street Page 3		Page 11
	Super Street Page 4		Page 12
	Cut away view

Taken from the old Vegas Racing.com/Quad page

Performance parts.
Cams:
Engle Cams www.englecams.com
CompCams camhelp@compcams.com
Mantapart www.mantapart.com
Crane E-mail them ONLY customerservice@cranecams.com

Heads:
Mantapart www.mantapart.com
or me

Crank, Block, Rods:
Eagle 2.4 Only any eagle rep can get them PN# CRS5710C3D
Pauter www.pauter.com
Crower www.crower.com
GM (stock parts)or once again Mantapart.

Headers:
no one makes them.
You would have to have one custom made. Or the Stock 89-92 HO
Piece flows best.

Chips, ECM/ECU (95) :
Superchips www.superchips.com
GM (HO-W41) www.gmpartsdirect.com
Mantapart www.mantapart.com
Jet www.jetchips.com
S-AFC www.apexi.com

Flywheels
Fidanza www.aluminumflywheels.com

Valve Springs:
Mantapart www.mantapart.com
Crane Part # CRN-99846-16 www.summitracing.com

Valves/Valve Guides:
www.sivalves.com

Pistons
Ross www.rosspistons.com
Wiseco www.wiseco.com
JE Piston www.jepistons.com

95 and SOHC Intake Manifold