Last update:

08/03/2005

  Engine Data 2.0 16V

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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

 
General
Engine management EEC V / SEFI
Emission standard 96 EEC
Engine code N3A
Firing order 1-3-4-2
Bore mm 86.0
Stroke mm 86.0
Cubic capacity cc 1998
Compression ratio 9.8:1
Power output (EEC) kW 100
  (PS) (136)
  at rpm6300
Torque (EEC) Nm 175
  at rpm4200
Idle speed (with manual transmission) rpm875
(with automatic transmission) rpm800
Max. permitted engine speed Continuous rpm 6450
  Intermittent 6675 rpm
Spark plugs AGPR22C1
Cylinder block  
Cast mark 20
Cylinder bore . standard class 1 mm 86.000 - 86.010
Cylinder bore . standard class 2 mm 86.010 - 86.020
Cylinder bore . oversize 0.15 mm 86.160 - 86.170
Cylinder bore . oversize 0.5 mm 86.500 - 86.510
Number of main bearings 5
Track main bearing width (excl. thrust half rings). standard. mm 21.17 - 21.23
Fitted main bearing shells
Vertical inner . service engine standard (yellow) mm 54.993 - 55.020
Standard mm 55.003 - 55.030
Vertical inner . 1st undersize 0.05 mm 54.953 - 54.980
Vertical inner . 2nd undersize 0.25 mm 54.753 - 54.780
Vertical inner . 3rd undersize 0.50 mm 55.503 - 54.530
Main bearing parent bore . standard mm 59.287 - 59.300
Main bearing parent bore . oversize 0.40 (black) mm 59.687 - 59.700
Crankshaft
End float mm 0.093 - 0.303
Main bearing journal . standard (yellow) mm 54.98 - 54.99
Main bearing journal . (red) mm 54.99 - 55.00
Main bearing journal . undersize 0.25 (green) mm 54.73 - 54.75
Main bearing journal to shell clearance mm 0.011 - 0.048
Big-end bearing journal . standard mm 50.89 - 50.91
Big-end bearing journal . undersize 0.25 (green) mm 50.64 - 50.66
Thrust half ring thickness. standard mm 2.301 - 2.351
Thrust half ring. over-width 0.38 (yellow) mm 2.491 - 2.541
Track bearing journal width. standard mm 26.025 - 26.075
Track bearing journal width. oversize 0.38 (yellow) mm 26.405 - 26.455
Connecting rods
Bore . large eye mm53.890 - 53.910
Bore . small eye mm20.589 - 20.609
Fitted big-end bearing shells
Vertical inner . standard mm50.916 - 50.950
Vertical inner . 1st undersize 0.25 mm50.666 - 50.700
Vertical inner . 2nd undersize 0.50 mm50.416 - 50.150
Big-end bearing journal to shell clearance mm0.006 - 0.060
Big-end bearing end float mm0.09 - 0.31
Camshafts
Number of camshaft bearings 2 x 5
Drive Single roller chain.
  hydraulic chain tensioner
Camshaft end float 0.02 - 0.26
Lift - cam. inlet mm 9.99
Lift - cam. exhaust mm 9.16
Cam length (between heel and tip). inlet mm 51.87 - 52.10
Cam length (between heel and tip). exhaust mm 51.04 - 51.27
Valve timing. inlet closes before TDC 9
Valve timing. inlet closes after BDC 59
Valve timing. exhaust opens before BDC 57
Valve timing. exhaust closes after TDC 11
Bearing journal - camshaft mm 25.96 - 25.98
Bearing inside diameter mm26.00 - 26.03
Pistons
Piston (not run). service engine standard mm 85.980 - 86.000
Piston (not run). oversize 0.15 mm 86.130 - 86.150
Piston (not run). 0.50 mm 86.470 - 86.490
Piston installation clearance (not run). Production mm 0.02 - 0.04
Piston installation clearance (not run). service engine mm 0.01 - 0.04
Piston pin length mm 63.4
Piston pin .white mm 20.622 - 20.625
Piston pin . red mm 20.625 - 20.628
Piston pin . blue mm 20.628 - 20.631
Clearance in piston (colour match) mm 0.008 - 0.014
Interference fit in small end bore mm 0.018 - 0.039
Piston ring gap (installed). top mm 0.30 - 0.60
Piston ring gap (installed). middle mm 0.50 - 0.80
Piston ring gap (installed). bil ring (three-part) mm 0.40 - 1.50
Ring gap position (piston ring gaps distributed
equally around piston circumference; this also
applies to gap of oil intermediate rings in relation to support spring gap.)
Valves
Valve timing DOHC
Valve clearances Hydraulic tappets
Hydraulic tappet mm 30
Hydraulic tappet clearance in housing mm 0.025 - 0.071
Valve length. inlet mm 111.67 - 112.13
Valve length. exhaust mm 111.37 - 111.83
Valve head . inlet mm 33.5
Valve head . exhaust mm 30
Valve stem standard. inlet mm 7.025 - 7.043
Valve stem standard. exhaust mm 6.999 - 7.017
Valve stem oversize 0.2. inlet mm 7.225 - 7.243
Valve stem oversize 0.2. exhaust mm 7.199 - 7.217
Valve stem oversize 0.4. inlet mm 7.425 - 7.443
Valve stem oversize 0.4. exhaust mm 7.399 - 7.417
Valve stem guide clearance. inlet mm 0.020 - 0.069
Valve stem guide clearance. exhaust mm 0.046 - 0.095
Colour code - spring Red
Free valve spring height mm 44.8
Inlet and exhaust spring strengths are identical
Spring strength. valve open N 635
Spring strength. valve closed N 210
Spring height (compressed). valve open mm 28.0
Spring height (compressed). valve closed mm 38.0
Valve spring inside mm 17.2
Valve spring wire mm 3.7
Number of turns 7.4
Lubrication
Oil pressure (with SAE 10W/30 and
80C oil temperature) at 800 /min
bar1.60
Oil pressure (with SAE 10W/30 and
80C oil temperature) at 2000/min
bar3.10
Pressure relief valve opens at bar3.70 - 4.60
Oil pressure warning light comes on at bar0.30 - 0.50
Oil pump rotor/housing clearance mm 0.154 - 0.304
Oil pump. inner/outer rotor gap mm 0.05 - 0.20
Oil pump. sealing surface/rotor axial clearance mm 0.039 - 0.104
Cylinder head with valve seat inserts
Cast mark 20
Upper correction angle (production)  inlet/exhaust 15/20
Lower correction angle (production) inlet/exhaust 30/30
Valve seat angle 45/30
Valve seat width. inlet mm 1.17 - 2.02
Valve seat width. exhaust mm 1.34 - 2.19
Valve guide inner (inlet/exhaust valve). standard mm 7.063 - 7.094
Camshaft bearing parent bore . (all) mm 26.00 - 26.03
Shims for the sump
Range of adjustment Available shims Colour coding
0 0.25 mm No adjustment  
0.26 0.29 mm 0.15mm Silver
0.30 0.44 mm 0.30 mm Pale blue
0.45 0.59 mm 0.45 mm red
0.60 0.75 mm 0.60 mm black
Lubricants. Adhesives and Sealers
  Ford Specification
Transmission fluid ESD-M2C186-A
Coolant ESD-M97B49-A
Sealing compound. front crankshaft oil seal carrier. Loctite 518 WSK-M2G348-A5
Sealing compound. sump. Hylosil 502WSK-M4G320-A
Adhesive sealing compound. coolant pump elbow flange. Loctite 243 WSK-M2G349-A7
Adhesive sealing compound. coolant temperature display sender. Loctite 243 WSK-M2G349-A7
Lubricant for O-ring of crankshaft position sensor (CKP) sensor SM1C-115-A
Lubricant for clutch release bearing guide sleeve ESD-M1C-220-A
Lubricant for transmission input shaft splines ESD-M1C-220-A
Power steering fluid SQM 2C-9010-A
Thread locking material. Loctite 270SDM-M4G9107-A
Spark plug thread. Never Seez ESE-M1244-A
Thread locking compound. power steering pump to bracket. Loctite 270SDM-M4G9107-A
Filling capacity
Description Litres
Engine oil. first filling with filter 5.1
Engine oil. oil change. with filter change 4.25
Engine oil. oil change. without filter change 4.0
Coolant 7.5

Engine Oil
Ambient Temperature Designation Specification
-10 to above 40 C Ford Multigrade SuperSAE 20W50 API/SG/CD Engine Oil
-15 to above 40 C Ford Multigrade Super SAE 15W40 API/SG/CD Engine Oil
-20 to above 40 C Ford Multigrade Super SAE 10W30 API/SG/CD Engine Oil
 -20 to above 40 C XR+ High-performance SAE 10W40 API/SG/CD High-lubricity Engine Oil
 -30 to above 40 C Ford Formula S Synthetic  Engine Oil SAE 5W50 API/SG/CD
 -30 to above 40 C Synthetic/Semi-synthetic  Engine Oil SAE 5W40 API/SG/CD
40 to below -30 C Ford Multigrade Super  Engine Oil SAE 5W30 API/SG/CD
The engine oil to specification SAE 5W30 API/SG/CD has only been approved for use in northern European countries.
If engine oils of other brands are used. it is imperative to ensure that these conform to API SG/CD or better in the particular viscosity class.

Torques
 
General Nm lbf.ft
Hose clips 4 3
Engine undershields to front crossmember 19 14
Rear axle reinforcing bar 49 36
Front axle reinforcing bar 80 59
Front axle to side members 80 59
Exhaust gas recirculation (EGR) Nm lbf.ft
EGR tube to exhaust manifold 75 56
EGR tube bracket to cylinder head 23 17
Flange on connecting pipe to inlet manifold 23 17
Exhaust Nm lbf.ft
Exhaust system heat shield to cylinder head 7 5
Exhaust mounting to transmission 44 32
Exhaust mounting to transmission crossmember 47 35
Exhaust mounting to engine 47 35
Exhaust flange bolts 47 35
Catalytic converter to exhaust manifold 47 35
Catalytic converter to bracket 47 35
Catalytic converter heat shield 23 17
Inlet manifold Nm Lbf.ft
Inlet manifold bracket 23 17
Studs 14 10
Retaining nuts 22 17
Throttle housing 10 7
Idle speed control (ISC) valve 10 7
Exhaust manifold Nm lbf.ft
Studs 14 10
Retaining nuts 23 17
Exhaust gas recirculation (EGR) valve 10 7
Alternator Nm lbf.ft
Alternator bracket to cylinder block 47 35
Transmission Nm lbf.ft
Earth lead to transmission 44 32
Torque converter to drive plate 47 35
Starter motor 44 32
Engine/transmission flange bolts 44 32
Bolt - adaptor plate to transmission 11 8
Driveshaft to rear axle 66 49
Driveshaft centre bearing to floor assembly 21 15
Driveshaft to vibration damper 78 58
Oil dipstick tube 10 7
Transmission crossmember to floor assembly 36 27
Transmission crossmember to transmission 62 46
Oil line bracket to engine mounting 50 37
Air Conditioning Nm lbf.ft
Air conditioning compressor to cylinder block 25 18
Air conditioning compressor bracket to cylinder block 47 35
Coolant circuit Nm lbf.ft
Water pump 23 17
Coolant temperature display sender 6 4
Thermostat housing 10 7
Engine coolant temperature (ECT) sensor 12 9
Angle connector to water pump 14 10
Water pump blanking plug 16 12
Blanking cover for rear coolant outlet 20 15
Steering Nm lbf.ft
Intermediate shaft to steering shaft 18 13
Power-assisted steering pump to bracket 23 17
Power-assisted steering pump pulley 25 18
Engine mounting Nm lbf.ft
Engine mounting nuts 50 37
Engine mounting bracket to cylinder block 47 35
Oil circuit Nm lbf.ft
Oil drain plug 25 18
Oil pressure switch. 27 20
Oil filter mounting 21 15
Oil filter 15 11
Oil baffle to cylinder block 21 15
Oil pump 12  9
Oil intake pipe to cylinder block 13 10
Sump to cylinder block (studs) 9 7
Sump to cylinder block (nuts and bolts) 11 8
Power steering Nm lbf.ft
Power-assisted steering pump to bracket 23 17
Pulley to power-assisted steering pump 25 18
Cylinder block Nm lbf.ft
Lower timing chain cover 10 7
Rear oil seal housing 13 10
Front oil seal housing 26 19
Crankshaft position/speed sensor 4 3
Timing chain guide rail M6 12 9
Timing chain guide rail M8 26 19
Crankcase ventilation tube bracket 9 7
Main bearing caps 97 72
Big-end bearing cap. 1st stage 7 5
Big-end bearing cap. 2nd stage 16 12
Big-end bearing cap. 3rd stage 90 90
Crankshaft oscillation damper. 1st stage 52 38
Crankshaft oscillation damper. 2nd stage 85 85
Flywheel 87 64
Oil pump chain tensioner arm 12 9
Oil pump sprocket 18 13
Clutch pressure plate 24 18
Cylinder head Nm lbf.ft
Cylinder head. 1st stage 10 7
Cylinder head. 2nd stage 35 26
Cylinder head. 3rd stage 90 90
Cylinder head. 4th stage 90 90
Cylinder head cover. 1st stage 3 2
Cylinder head cover. 2nd stage 9 7
Ignition coil covers 5 4
Auxiliary cylinder head bolts (x3) 38 28
Upper timing chain cover 11 8
Fuel rail 24 18
Fuel pressure regulator 10 7
Camshaft bearing caps 24 18
Camshaft sprockets 59 44
Engine lifting eyes 25 18
Studs to cylinder head (x20) 20 15
Blanking plugs 52 38
Rear blanking cover for rear coolant outlet 20 15
Spark plugs 18 13
 

 

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