Last update:

08/03/2005

  Engine Data 2.9 12V

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Engine Data 2.0 8V
Engine Data 2.0 16V
Engine Data 2.3 16v
Engine Data 2.9 12V
Engine Data 2.9 24v
Engine Data 2.5 TD
Ford-Cosworth 24V
2.3 Engine Overview
A4LDE Auto Box
MT75 Manual Box
Vacuum Pipes
Wiring Loom Diagrams

  Engine Data
 
Emission standard 93EEC
Identification code BRG
Firing order 1-4-2-5-3-6
Bore 93.03
Stroke 71.99mm
Cubic capacity 2936cc
Compression ratio 9.0:1
Power output (EEC) 107 kW
145 PS at 5500 rev/min
Torque (EEC) 168 Nm at 2500 rev/min
Max permissible engine speed
Continuous rev 5800 / min
Intermittent 5800 / min
Spark plugs AGRF32C1
Dimensions
Cylinder block
Castmark F
Cylinder bore diameter
standard class 1 93.010-93.020 mm
Cylinder bore diameter
standard class 2 93.020-93.030 mm
Cylinder bore diameter
standard class 3 93.030-93.040 mm
Cylinder bore diameter
standard class 4 93.040-93.050 mm
Cylinder bore diameter
oversize class A 93.520-93.530 mm
Cylinder bore diameter
oversize class B 93.530-93.540 mm
Cylinder bore diameter
oversize class C 93.540-93.550 mm
Cylinder bore diameter
service standard 93.040-93.050 mm
Cylinder bore diameter
oversize 0.5 93.540-93.550 mm
Cylinder bore diameter
oversize 1.0 94.040-94.050 mm
Fitted main bearing shells
vertical diameter standard 57.008-57.042 mm
Fitted main bearing shells
vertical diameter undersize 0.254 56.754-56.788 mm
Centre main bearing width 22.610-22.660 mm
Number of main bearings 4
Main bearing parent bore diameter standard 60.620-60.634 mm
Main bearing parent bore diameter oversize 0.38 61.000-61.014 mm
Camshaft bearing parent bore diameter front 47.025-47.060 mm
Camshaft bearing parent bore diameter (without bearing bushes) 46.645-46.680 mm
middle1
Camshaft bearing parent bore diameter middle2 46.265-46.300 mm
Camshaft bearing parent bore diameter rear 45.885-45.920 mm
Crankshaft
Main bearing journal diameter standard 56.980-57.000 mm
Main bearing journal diameter undersize 0.254 56.726-56.746 mm
Main bearing journal to shell clearance 0.008-0.056 mm
Centre main bearing shoulder width standard 26.390-26.440 mm
Centre main bearing shoulder width oversize 0.38 26.771-26.821 mm
Flanged bearing shell width standard 26.190-26.260 mm
Flanged bearing shell width oversize 0.38 26.570-26.640 mm
Endfloat 0.080-0.240 mm
Big-end bearing journal diameter standard 53.980-54.000 mm
Big-end bearing journal diameter undersize 0.254 53.726-53.746 mm
Big-end bearing journal to shell clearance 0.006-0.064 mm
Pistons
Piston diameter standard 1 92.972-92.982 mm
Piston diameter standard 2 92.982-92.992 mm
Piston diameter standard 3 92.992-93.002 mm
Piston diameter standard 4 93.002-93.012 mm
Piston diameter service standard 93.000-93.020 mm
Piston diameter service oversize 0.5 93.500-93.520 mm
Piston diameter service oversize 1.0 94.000-94.020 mm
Piston clearance in bore (unused) 0.028-0.048 mm
Piston ring gaps (fitted) top 0.030-0.050 mm
Piston ring gaps (fitted) middle 0.030-0.050 mm
Piston ring gaps (fitted) bottom 0.400-1.400 mm
Ring gap position top (from the expander ring gap) 150
Ring gap position - middle 150 from the expander ring gap (opposite the top compression ring)
Lower oil control ring - top intermediate ring 25mm from the expander ring gap Expander opposite the marked side of the piston
Lower intermediate ring 25mm from the expander ring gap (opposite the top intermediate ring)
Piston Pins
Pin diameter - red 23.994-23.997 mm
Pin diameter - blue 23.997-24.000 mm
Clearance in piston 0.005-0.011 mm
Interference fit in small - endbore 0.018-0.042 mm
Connecting rods
Bore diameter (without bearing shells) -big end 56.820-56.840 mm
Bore diameter (without bearing shells) - small end 23.958-23.976 mm
Fitted big-end bearing shells -vertical inside diameter standard 54.006-54.046 mm
Fitted big-end bearing shells - vertical inside diameter oversize 53.752-53.792 mm
Cylinder head
Castmark K
Upper correction angle (production) - inlet/exhaust 75/65
Service correction cutter 75/-
Lower correction angle (production) - inlet 18
Service correction cutter 15
Stem bore (inlet and exhaust valve) - standard 8.063-8.088 mm
Stem bore (inlet and exhaust valve) -oversize 0.2 8.263-8.288 mm
Stem bore (inlet and exhaust valve) - oversize 0.4 8.463-8.488 mm
Stem bore (inlet and exhaust valve) - oversize 0.6 8.663-8.688 mm
Stem bore (inlet and exhaust valve) - oversize 0.8 8.863-8.888 mm
Camshaft
Drive Single roller chain 3/8''
Valve timing - inlet opens 30 BTDC
Valve timing - inlet closes 66 ABDC
Valve timing - exhaust opens 76 BBDC
Valve timing - exhaust closes 20 ATDC
Cam lift - inlet 6.54 mm
Cam lift - exhaust 6.54 mm
Cam length (between heel and toe) - inlet 36.215-36.405 mm
Cam length (between heel and toe) - exhaust 36.215-36.405 mm
Thickness of camshaft thrustplate 4.020-4.050 mm
Camshaft end float 0.065-0.165 mm
Number of camshaft bearings 4
Bearing diameter-camshaft bearing journal. - front 43.903-43.923 mm
Bearing diameter-camshaft bearing journal - middle 1 43.522-43.542 mm
Bearing diameter-camshaft bearing journal - middle 2 43.141-43.161 mm
Bearing diameter-camshaft bearing journal - rear 42.760-42.780 mm
Bearing bush inside diameter - front 43.948-43.968 mm
Bearing bush inside diameter - middle1 43.567-43.587 mm
Bearing bush inside diameter - middle2 43.186-43.206 mm
Bearing bush inside diameter - rear 24.805-42.825 mm
Valves
Valve tappet diameter 22.200-22.212 mm
Tappet clearance in housing mm fitted 0.023-0.060 mm
Free valve spring height 53 mm
Spring force - valve open N800-867
Spring force - valve closed N417-467
Inlet valve
Valve head diameter mm not fitted 41.85-42.24 mm
Valve length 104.65-105.35 mm
Valve stem diameter - .standard 8.025-8.043 mm
Valve stem diameter - oversize 0.2 8.225-8.243 mm
Valve stem diameter - oversize0.4 8.425-8.443 mm
Valve stem diameter - oversize0.6 8.625-8.643 mm
Valve stem diameter - oversize0.8 8.825-8.843 mm
Valve stem clearance in guide 0.020-0.063 mm
Valve lift - at zero valve clearance 9.54 mm
Viton oil control ring Part No. 86TM6571AB
Exhaust valve
Valve head diameter 35.83-36.21 mm
Valve length 104.60-105.60 mm
Valve stem diameter - standard 7.999-8.017 mm
Valve stem diameter - oversize0.2 8.199-8.217 mm
Valve stem diameter - oversize0.4 8.399-8.417 mm
Valve stem diameter - oversize0.6 8.599-8.617 mm
Valve stem diameter - oversize0.8 8.799-8.817 mm
Valve stem clearance in guide 0.046-0.089 mm
Valve lift at zero valve clearance 9.54 mm
Viton oil control ring PartNo.86TM6571AB
 
Oil pump
Rotor/housing clearance mm0.154-0.304
Inner/outer rotor clearance mm0.050-0.200
Rotor endfloat at mating face mm0.035-0.100
Lubricants - Adhesives and Sealers
Description Ford Specification
Sealer for vibration damper bolt, joint between the cylinder head ventilation plenum and the cylinder block, cylinder head cover flange mating faces SPM-2G-3121
Sealer, crankshaft main bearing caps to the cylinder block, sump to cylinder block coolant pump and timing cover to cylinder block (Loctite518)-A ESKM-4G-269
Sealer for contact faces of the cylinder block and cylinder heads and the inlet manifold flange (Wellseal)-F SPM-4G-9112
Spark plug thread lubricant (NeverSeez) ESE-M1244-A
High-temperature grease for torque converter guide bore ESDM-1C220-A
Motor oil
Ambient temperature Designation Specification
-20 to over 40C Ford Multigrade Super Motor Oil SAE10W30API/SH/CDEC
If engine oils of other brands are used, it is imperative to ensure that these conform to APISH/CDorbetter in the particular viscosity class
Description Litres
Engine oil - initial fill 4.8
Oil change excl filter 4.0
Oil change incl filter 4.25


 

Torques    
General Nm lbf.ft.
Engine hood hinges 23 17
Wiring loom bracket to fender apron panel 10 7
 
Inlet Manifold Nm lbf.ft
Inlet manifold - stage1 6 4
Inlet manifold - stage2 12 9
Inlet manifold - stage3 18 13
Inlet manifold - stage4 23 17
after a 15min warm-up at 1000rev/min Stage 5 23 17
Fuel rail to inlet manifold 12 9
Intake air temperature (IAT) sensor 15 11
Inlet air plenum chamber to inlet manifold 9 7
 
Exhaustmanifold Nm lbf.ft
Exhaust manifold to cylinder head 28 21
Heatshield to exhaust manifold 9 7
Exhaust pipe to exhaust manifold 47 35
Exhaust pipe to catalytic converter 45 33
Alternator Nm lbf.ft
Alternator bracket 25 18
Alternator to bracket 25 18
   
Transmission Nm lbf.ft
Flange bolts (all) 44 32
Torque converter to drive plate 44 32
Starter motor to transmission 44 32
Air conditioning system Nm lbf.ft
Belt tensioner for drive belt of air conditioning compressor 41 30
Air conditioning compressor to cylinder block 44 32
Coolant circuit Nm lbf.ft
Coolant pump 9 7
Belt pulley to coolant pump 25 18
Thermostat housing / bypass connector 10 7
 
Engine coolant temperature (ECT) sensor 15 11
 
Coolan ttemperature sender unit 6 4
 
Coolant drain plug 23 17
 
Steering Nm lbf.ft
 
Power steering pump to bracket 25 18
 
Power steering pump pulley 25 18
 
Intermediate shaft to steering shaft 18 13
 
Oil circuit Nm lbf.ft
 
Oil intake pipe tooil pump 11 8
 
Oil pump to cylinder block 19 14
 
Oil pump cover 11 8
 
Sump.stage1 5 4
 
Sump.stage2 8 6
 
Oil baffle 19 14
 
Oil drain plug 25 18
 
Oil pressure switch 27 20
 
Oil filter 15 11
 
Bracket-oil dipstick tube 44 32
 
   
 
Frontaxle Nm lbf.ft
 
Transverse brace to front axle 80 59
 
Front axle to side member 80 59
 
Suspension arm to spindle carrier 83 61
 
Link rod to stabiliser bar 47 35
 
Trackrod to spindle carrier 63 46
 
Lower engine mounting to crossmember 50 37
 
   
 
Cylinder block Nm lbf.ft
 
Camshaft sprocket 64 47
 
Camshaft thrustplate 11 8
 
Chain guide to cylinder block 11 8
 
Timing chain tensioner to cylinder block 10 7
 
Vibrationdamperbolttocrankshaft.stage1 45 33
 
Vibration damper bolt to crankshaft.stage2 85 85
 
Timing cover to cylinder block 19 14
 
Main bearing caps 97 72
 
Big-end bearing caps (connecting rods and big-end bearing bolts identification codes 6AA and KX110 respectively) 30 22
 
 
Big-end bearing caps (connecting rods and big-end bearing bolts identification codes 5AB and KX900 respectively).stage1 20 15
 
 
Big-end bearing caps.stage2 90 90
 
Spark plugs 32 24
 
Distributor retaining plate 19 14
 
Flywheel pressure plate to crankshaft.stage1 30 22
 
Flywheel pressure plate to crankshaft.stage2 85 85
 
Clutch pressure plate to flywheel 23 17
 
Bracket with engine mounting bracket to cylinder block 50 37
 
   
 
Cylinder Head Nm lbf.ft
 
Thermostat housing / bypass connector 10 7
 
Cylinder head (internal Torxbolts).stage1 38 28
 
Cylinder head (internal Torxbolts).stage2 73 54
 
Cylinder head (internal Torxbolts).stage3 90 90
 
Cylinder head cover 7 5
 
Rocker shaft.stage1 32 24
 
Rocker shaft.stage2 90 90
 
Exhaust manifold to cylinder head 28 21
 
Heatshield to exhaust manifold 9 7



 

 

 

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