“. Despite the balance shafts, after looking into it 2.4L is the 'maximum' size of an inline 4.” It’s not. Porsche for example used to fit a 3.0 4 pot in the 968. Fewer but larger cylinders means more low speed pull but at the sacrifice of high speed refinement. The smaller E200 buses we run in town use a 4cyl Cummins diesel that’ll be a fair capacity too, I’ll try to find out how big. Edit: It’s 4.5 litre also used in the new Route Master apparently.
As far as i am aware, the largest in-line 4cyl petrol engine fitted to a production car was the 1961-1963 Pontiac Tempest, which was a 3.2 litre (195 cubic inch). This was simply one bank of the 389 cubic inch V8 and was done because it could be assembled on the same line. It was not a great engine, hence the short life span (replaced by a 6 cyl), being quite rough even when running properly, but particularly rough when 'out of tune'!.
Including diesel, for 'cars' (if we include 4x4's), the prize would probably go to Mitsubishi, which (still) uses a 3.2 litre in the Shogun/Pajero.
Going back to petrol, there is also the 2.7 litre 4 cyl used in various Toyota models. Not that common here where we preferred the diesel engines, but loads sold world-wide (and no doubt most still providing reliable service!)
But the largest production inline 4 (used in a road vehicle), i believe, is the Detroit Diesel Series 50, which uses an 8.5 litre making up to 350 bhp. I don't think you get them in this country, but a popular powerplant for trucks and buses in USA and Australia.
Excluding the 'production' part, (i think) the biggest inline 4 ever used on the road would probably have been the 1910 Fiat S76 built to take the land speed record of the time. Often referred to as 'The Beast of Turin', this used a 28,353cc(!) in-line 4 aero engine. Brought back to life and currently owned by Brit Duncan Pittaway, this fantastic machine is regularly used on the road and demonstrated at various venues such as Goodwood. Look it up on YouTube if you are interested, it is an amazing thing to see running, especially the frankly terrifying looking start up!.
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