Last update:

08/03/2005

  Engine Data 2.3 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

 
Dimensions
Cylinder block
Cast mark 2.3
Cylinder bore diameter. standard class 1 mm  89.60 - 89.61
Cylinder bore diameter. standard class 2 mm  89.61 - 89.62
Number of main bearings 5
Thrust bearing width (without thrust half washers) standard mm  21.17 - 21.23
Fitted main bearing shells
Vertical inner diameter. standard mm  55.003 - 55.030
Vertical inner diameter. 1st undersize 0.02 mm  54.993 - 55.020
Vertical inner diameter. 2nd undersize 0.25 mm  54.753 - 54.780
Vertical inner diameter. 3rd undersize 0.50 mm  54.503 - 54.530
Vertical inner diameter. 4th undersize 0.75 mm  54.253 - 54.280
Main bearing parent bore diameter. standard mm  59.287 - 59.300
Main bearing parent bore diameter. oversize 0.40 mm  59.687 - 59.700
Crankshaft
End float mm  0.093 - 0.303
Main bearing journal diameter. standard mm  54.98 - 55.00
Main bearing journal diameter. undersize (green) mm  54.73 - 54.75
Bearing shell to main bearing journal clearance mm  0.011 - 0.048
Big end journal diameter. standard mm  50.89 - 50.91
Big end journal diameter. undersize 0.25 (green) mm  50.64 - 50.66
Thrust half washer thickness. standard mm  2.301 - 2.351
Thrust half washer thickness. oversize 0.38 mm   (yellow) mm  2.491 - 2.541
Thrust bearing journal width. standard mm  26.025 - 26.075
Thrust bearing journal width. oversize 0.38 (yellow) mm  26.405 - 26.455
Connecting rod
Bore diameter. big end mm  53.89 - 53.91
Bore diameter. small end mm  20.589 - 20.609
Fitted big-end bearing shells
Vertical inner diameter. standard mm  50.916 - 50.950
Vertical inner diameter. 1st undersize 0.025 mm  50.892 - 50.926
Vertical inner diameter. 2nd undersize 0.25 mm  50.666 - 50.700
Vertical inner diameter. 3rd undersize 0.50 mm  50.416 - 50.450
Vertical inner diameter. 4th undersize 0.75 mm  50.166 - 50.200
Vertical inner diameter. 5th undersize 1.00 mm  49.916 - 49.950
Big-end bearing journal to shell clearance mm  0.006 - 0.060
Big-end bearing end float mm  0.090 - 0.3610
Uncoated pistons (unused)
Piston diameter. class 1 mm  89.560 - 89.570
Piston diameter. class 2 mm  89.570 - 89.580
Coated pistons (unused)
Piston diameter. class 1 mm  89.580 - 89.610
Piston diameter. class 2 mm  89.590 - 89.620
Piston clearance in cylinder bore (unused. uncoated piston) mm  0.03 - 0.05
Piston clearance in cylinder bore (unused. coated piston) mm  -0.01 - +0.03
Piston pin length mm  63.0 - 63.8
Interference fit in small-end bore mm  0.016 - 0.042
Piston ring gap (installed). top mm  0.3 - 0.46
Piston ring gap (installed). middle mm  0.5 - 0.76
Piston ring gap (installed). bottom mm  0.15 - 0.71
Ring gap positions Set the ring gaps at 90 to each other around the piston circumference; this alsoapplies to each part of the oil scraper ring.
Cylinder head with valve seat inserts*
Cast mark 2.3
Upper correction angle. inlet valve (production) 30
Upper correction angle. exhaust valve (production) 30
Valve seat angle 44.5 - 45.5
Valve seat width. inlet mm  1.18 - 2.02
Valve seat width. exhaust mm  1.35 - 2.19
Lower correction angle. inlet (production) 75
Lower correction angle. exhaust (production) 75
Valve stem guide diameter. inlet mm  7.063 - 7.094
Valve stem guide diameter. exhaust mm  7.063 - 7.094
Camshaft bearing parent bore diameter mm  26.00 - 26.03
Camshafts
Number of camshaft bearings. each camshaft 5
Drive Single roller chain
Camshaft end float mm  0.02 - 0.26
Cam lift. inlet mm  9.4
Cam lift. exhaust mm  8.75
Valve timing. inlet opens BTDC CS9
Valve timing. inlet closes ABDC CS51
Valve timing. exhaust opens BBDC CS48
Valve timing. exhaust closes ATDC CS12
Camshaft bearing journal diameter mm  25.96 - 25.98
Valves
Valve timing DOHC
Valve clearance adjustment Hydraulic tappets
Hydraulic tappet diameter mm  30
Hydraulic tappet clearance in housing mm  0.025 - 0.071
Inlet valve length mm  111.67 - 112.13
Exhaust valve length mm  111.37 - 111.83
Valve head diameter. inlet mm  33.5
Valve head diameter. exhaust mm  30.0
Valve stem diameter. standard inlet mm  7.025 - 7.043
Valve stem diameter. standard exhaust mm  6.999 - 7.017
Valve stem diameter. oversize 0.2 inlet mm  7.225 - 7.243
Valve stem diameter. oversize 0.2 exhaust mm  7.199 - 7.217
Valve stem diameter. oversize 0.4 inlet mm  7.425 - 7.443
Valve stem diameter. oversize 0.4 exhaust mm  7.399 - 7.417
Inlet valve stem guide clearance mm  0.020 - 0.069
Exhaust valve stem guide clearance mm  0.046 - 0.095
Free valve spring height mm  43.6
Spring height (compressed) mm  max. 26.5
Valve spring inner diameter mm  17.2
Valve spring coil diameter mm  3.7
Number of turns 7.4
Lubrication
Oil pressure at 800 rpm (with SAE 10W/30 and 80C oil temperature) bar1.60
Oil pressure at 2000 rpm (with SAE 10W/30 and 80C oil temperature) bar3.10
Pressure relief valve opens at bar3.70 - 4.60
Oil control light comes on at bar0.30 - 0.50
Oil pump rotor/housing clearance mm  0.154 - 0.304
Inner/outer rotor clearance mm  0.05 - 0.20
Rotor end float at mating face mm  0.039 - 0.104
Balancer shaft housing
Balancer shaft end float mm  0.050 - 0.100
Balancer shaft radial clearance mm  0.022 - 0.074

 

Distance plate for balancer shaft housing
Range of adjustment
Available shims Colour coding
 0.26 - 0.29 mm  0.15 mm    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
 0.76 - 0.90 mm  0.75 mm    Green

 

Lubricants. Adhesives and Sealers  
Description Ford Specification
   
Coolant ESD-M97B49-A
Sealer. coolant temperature sensor. coolant pump angle connector. oil pressure switch (Loctite 243) WSK-M2G349-A7
Sealer for rear oil seal carrier to balancer shaft housing WSE-M4G323-A6
Lubricant for O-ring of crankshaft position/speed sensor (CPS) WSD-M1C226-A
Power steering fluid SQM-2C-9010-A
Lubricant for spark plug threads. HO2S sensor (`Never Seez') ESE-M1244-A
High-temperature grease ESDM-1C220-A
Silicone grease A960-M1C171-AA
Capacity
Description Litres
Engine oil. initial fill. with filter 5.1
Engine oil. oil change incl. filter (every 15.000 km) 4.25
Engine oil. oil change excl. filter 3.75

 

Engine oil
Ambient temperature Designation Specification
-10 to above 40C Ford Super Multigrade Engine Oil SAE 20W50 API/SG/CD
-15 to above 40C Ford Super Multigrade Engine Oil SAE 15W40 API/SH/CD
-20 to above 40C Ford Super Multigrade Engine Oil SAE 10W30 API/SH/CD EC
-20 to above 40C Ford XR+ High-performance High SAE 10W40 API/SH/CD EC
  -lubricity Engine Oil
-30 to above 40C Ford Formula S Synthetic Engine Oil SAE 5W50 API/SG/CD
-30 to above 40C Synthetic/Semi-synthetic Engine Oil SAE 5W40 API/SH/CD EC
+40 to below -30C Ford Super Multigrade 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 territories
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
Front axle reinforcing bar 80 59
Air conditioning compressor 47 35
Air baffle - fan motors 11 8
Hood hinges 23 17
EGR valve to bracket 24 18
EGR tube to exhaust manifold 75 55
EGR tube bracket to exhaust manifold 23 17
Transmission crossmember to body 36 27
Transmission crossmember to automatic transmission 62 46
Driveshaft to rear axle 66 49
Driveshaft centre bearing 21 15
Starter motor to automatic transmission 44 32
Automatic transmission to engine (flange bolts) 44 32
Starter motor bracket to cylinder block 44 32
Torque converter to engine drive plate 44 32
Earth lead to automatic transmission 44 32
Oil dipstick tube bracket to automatic transmission 44 32
Oil pipes to automatic transmission 25 18
Oil pipe bracket to automatic transmission 44 32
Engine mounting bracket to cylinder block 47 35
Engine mounting nuts 50 37
Steering Nm lbf.ft
Intermediate shaft to steering shaft 18 13
Steering gear - 1st stage 15 11
Steering gear - 2nd stage 90 90
Power steering pump to bracket 25 19
Power steering pump pulley 25 19
Exhaust system Nm lbf.ft
Front to rear exhaust pipe 47 35
Front exhaust pipe bracket to transmission crossmember 47 35
Catalytic converter to exhaust manifold 47 35
Catalytic converter bracket to automatic transmission 44 33
Catalytic converter bracket to body 47 35
Front catalytic converter bracket 24 18
Cylinder block Nm lbf.ft
Main bearing 97 72
Big end bearing. 1st stage 7 5
Big end bearing. 2nd stage 16 12
Big end bearing. 3rd stage 90 90
Balancer shaft housing to cylinder block. 1st stage 5 4
Balancer shaft housing to cylinder block. 2nd stage 17 13
Crankshaft rear oil seal carrier 15 11
Crankshaft pulley/vibration damper. 1st stage 52 38
Crankshaft pulley/vibration damper. 2nd stage 85 85
Clutch Disk and Pressure Plate 29 21
Flywheel 87 64
Lower timing chain cover 11 9
Crankshaft position/speed sensor 4 3
Cylinder Head Nm lbf.ft
Cylinder head bolts. 1st stage 10 7
Cylinder head bolts. 2nd stage 35 26
Cylinder head bolts. 3rd stage 90 90
Cylinder head bolts. 4th stage 90 90
Auxiliary cylinder head bolts 38 28
Camshaft bearing caps 24 18
Timing chain top guide 12 9
Timing chain bottom guide 26 19
Camshaft sprockets 59 44
Timing chain upper cover 11 8
Cylinder head cover. 1st stage 3 2
Cylinder head cover. 2nd stage 9 7
Camshaft position sensor (CMP sensor) 5 4
Spark plugs 18 13
DIS ignition coils 10 7
Ignition coil cover 5 4
Studs for exhaust manifold 14 10
Engine oil dipstick tube bracket 24 18
Engine lifting eye. rear right 25 18
Engine lifting eye. front left 47 35
Inlet manifold 22 16
Fuel rail 23 17
Throttle housing 10 7
Idle speed control valve 10 7
Engine coolant temperature sensor (ECT sensor) 27 20
Oil circuit Nm lbf.ft
Oil intake tube to balancer shaft housing 12 9
Sump to balancer shaft housing 12 9
Oil drain plug 24 18
Oil pressure switch 27 20
Oil filter connector 57 42
Oil pump 11 8
Oil pump sprocket 21 15
Oil pump cover 10 7
Oil pump sprocket 21 15
Oil pump drive chain upper guide 26 19
Oil pump drive chain lower guide 12 9
Oil pump drive chain tensioner 12 9
Balancer shaft housing Nm lbf.ft
Balancer shaft bearing caps to housing 12 9
Sprockets to shaft stub 19 14
Coolant circuit Nm lbf.ft
Coolant pump 23 17
 

 

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