Last update:

08/03/2005

  Engine Data 2.0 8V

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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
Description  
Engine management EEC V / SFI
Emission standard 96 EEC
Engine code NSD
Firing order 1 - 3 - 4 - 2
Bore mm  86.0
Stroke mm 86.0
Cubic capacity cc1998
Compression ratio 9.8 : 1
Power output (EEC) kW85
Power output (EEC) PS115
Power output (EEC). at rpm 5500
Torque (EEC) Nm167
Torque (EEC). at rpm 2500
Idle speed rpm 875
Maximum permissible engine speed. continuous rpm 5950
Maximum permissible engine speed. intermittent rpm 6175
 
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
Centre main bearing width (excl. thrust half rings) mm 21.17 - 21.23
Fitted main bearing shells
Vertical inside . service standard (yellow) mm 54.983 - 55.020
Vertical inside . standard mm 55.003 - 55.030
Vertical inside . 1st undersize 0.05 mm 54.953 - 54.980
Vertical inside . 2nd undersize 0.25 mm 54.753 - 54.780
Vertical inside . 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 j. standard mm 50.89 - 50.91
Big-end bearing journal j. 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 (yellow) mm 2.491 - 2.541
Width of centre main bearing journal. standard mm 26.025 - 26.075
Width of centre main bearing journal. oversize 0.38 (yellow) mm 26.405 - 26.455
Connecting rod
Bore . big-end mm 53.890 - 53.910
Bore . small end mm 20.589 - 20.609
Fitted big-end bearing shells
Vertical inside . standard mm mm 50.916 - 50.950
Vertical inside . 1st undersize (0.25 mm ) mm 50.666 - 50.700
Vertical inside . 2nd undersize (0.50 mm ) mm 50.416 - 50.150
Big-end bearing journal to shell clearance mm 0.006 - 0.060
Big-end bearing end float mm 0.09 - 0.31
Camshafts
Number of camshaft bearings 2 x 5
Drive Single roller chain.
  hydraulic chain tensioner
Camshaft end float mm 0.02 - 0.26
Cam lift. inlet mm 10.83
Cam lift. exhaust mm 10.83
Cam length (between heel and toe). inlet mm 52.71 - 52.94
Cam length (between heel and toe). exhaust mm 52.71 - 52.94
Inlet valve opens before TDC 9
Inlet valve closes after BDC 51
Exhaust valve opens before BDC 51
Exhaust valve closes after TDC 9
Camshaft bearing journal mm 25.96 - 25.98
Bearing inside diameter mm 26.00 - 26.03
Pistons
Uncoated piston - (unused). service standard mm 85.970 - 85.990
Uncoated piston - (unused). oversize 0.15 mm 86.120 - 86.140
Uncoated piston - (unused). oversize 0.50 mm 86.460 - 86.480
Piston clearance in bore (unused. piston uncoated). prod. mm 0.03 - 0.05
Piston clearance in bore (unused. piston uncoated). service mm 0.02 - 0.05
Coated piston - (unused). service standard mm 85.990 - 86.030
Coated piston - (unused). oversize 0.15 mm 86.140 - 86.180
Coated piston - (unused). oversize 0.50 mm 86.480 - 86.520
Piston clearance in bore (unused. piston coated). prod. mm 0.01 - 0.03
Piston clearance in bore (unused. piston coated). service mm 0.02 - 0.03
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 0.016 - 0.042
Piston ring gaps (fitted). top mm 0.30 - 0.60
Piston ring gaps (fitted). middle mm 0.50 - 0.80
Piston ring gaps (fitted). oil control ring (three part) mm 0.40 - 1.50
Ring gap positions Piston ring gaps should be distributed evenly around the piston circumference; this also applies to the gaps of the intermediate oil control rings in relation to the expander gap.
 
 
 
Valves
Valve timing DOHC
Valve clearances Hydraulic tappets
Hydraulic tappet mm 42
Hydraulic tappet clearance in housing mm 0.025 - 0.080
Valve length. inlet mm 108.24 - 108.70
Valve length. exhaust mm 108.68 - 109.20
Valve head . inlet mm 42.5 - 42.7
Valve head . exhaust mm 37.9 - 38.1
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 7.255 - 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. oversize 0.6 (inlet) mm 7.625 - 7.643
Valve stem. oversize 0.6 (exhaust) mm 7.599 - 7.617
Valve stem. oversize 0.8 (inlet) mm 7.825 - 7.843
Valve stem. oversize 0.8 (exhaust) mm 7.799 - 7.817
Valve stem clearance in guide. inlet mm 0.020 - 0.069
Valve stem clearance in guide. exhaust mm 0.046 - 0.095
Colour code. outer spring Green/Blue
Colour code. inner spring Green/Blue
Free valve spring height. outer spring mm 48.2
Free valve spring height. inner spring mm 49.2
Valve spring inner . outer spring mm 24
Valve spring inner . inner spring mm 17.5
Valve spring wire (oval profile). outer spring mm 4.1 x 4.95
Valve spring wire . inner spring mm 2.6
Number of turns. outer spring 6.83
Number of turns. inner spring 8.82
Lubrication  
Oil pressure at 875 rpm (with SAE 10W/30 oil at a temperature of 80C) bar1.60
Oil pressure at 2000 rpm (with SAE 10W/30 oil at a temperature of 80C) 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
Inner/outer rotor clearance mm 0.05 - 0.20
Rotor end float at mating face mm 0.014 - 0.079
Cylinder head with valve seat inserts
Cast mark 20
Upper correction angle (production). inlet/exhaust 25
Lower correction angle (production). inlet/exhaust 60
Valve seat angle 44.5 - 45
Valve seat width. inlet mm 1.33 - 2.19
Valve seat width. exhaust mm 1.68 - 2.54
Stem bore (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 to 0.25 mm  

No adjustment

0.26 to 0.29 mm  

0.15 mm  Silver

0.30 to 0.44 mm  

0.30 mm  Pale blue

0.45 to 0.59 mm  

0.45 mm  Red

0.60 to 0.75 mm

0.60 mm  Black

Lubricants. Adhesives and Sealers
Description Ford Specification
Transmission fluid ESD-M2C186-A
Coolant ESD-M97B49-A
Sealer for front oil seal carrier (Loctite 518) WSK-M2G348-A5
Sealer for sump (Hylosil 502) WSK-M4G320-A
Sealer for coolant pump angle connector. coolant temperature sender unit. oil pressure WSK-M2G349-A7
switch (Loctite 243)  
Lubricant for O-ring of crankshaft position sensor (CKP) 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 compound (Loctite 270) SDM-M4G9107-A
Spark plug thread ('Never Seeze') ESE-M1244-A
Thread-locking compound. power steering pump to bracket (Loctite 270) SDM-M4G9107-A
Silicone grease A960-M1C171-AA
Capacity
Description Litres
Engine oil. initial fill including filter 5.1
Engine oil. oil change with filter change 4.25
Engine oil. oil change without filter change 4.00
Coolant 7.9
Engine oil

Ambient temperature

Designation

Specification

-10 to over 40 C

Ford Multigrade Super Engine Oil

SAE 20W50 API/SG/CD

-15 to over 40 C

Ford Multigrade Super Engine Oil

SAE 15W40 API/SH/CD

-20 to over 40 C

Ford Multigrade Super Engine Oil

 SAE 10W30 API/SH/CD EC

-20 to over 40 C

XR+ High-performance High-lubricity

SAE 10W40 API/SH/CD EC

Engine Oil

-30 to over 40 C

Ford Formula S Synthetic Engine Oil

SAE 5W50 API/SG/CD

-30 to over 40 C

Synthetic/Semi-synthetic Engine Oil

SAE 5W40 API/SH/CD EC

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 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  
  Nm lbf ft
General
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    
Exhaust system heat shield to cylinder head 7 5
Exhaust mounting to transmission 44 32
Exhaust mounting to transmission crossmember 47 35
Exhaust bracket to engine 47 35
Catalyst to exhaust manifold 47 35
Inlet manifold
Studs (coated with microcapsules) 14 10
Inlet manifold nuts 23 17
Throttle housing 10 7
Idle air control (IAC) valve 10 7
Exhaust manifold
Studs (coated with microcapsules) 17 13
Exhaust manifold nuts 23 17
Exhaust gas recirculation (EGR) valve 10 7
Transmission    
Earth lead to transmission 44 32
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
Air conditioning system  
Compressor to cylinder block 25 18
Coolant circuit    
Coolant pump 23 17
Coolant temperature gauge sender unit 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    
Intermediate shaft to steering shaft 18 13
Power steering pump to bracket 23 17
Power steering pump pulley 25 18
Engine mounting
Engine mounting nuts 50 37
Oil circuit    
Oil drain plug 25 18
Oil pressure switch 27 20
Oil filter mounting 21 15
Oil filter 14 10
Oil cooler 60 44
Oil baffle to cylinder block 21 15
Oil pump 12 9
Oil intake pipe to cylinder block 13 10
Sump to cylinder block (studs and nuts) 12 9
Power steering    
Power steering pump to bracket 25 18
Cylinder block  
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 breather 9 7
Main bearing caps 97 72
Big-end bearing caps. stage 1 7 5
Big-end bearing caps. stage 2 16 12
Big-end bearing caps. stage 3 90 90
Crankshaft vibration damper. stage 1 52 38
Crankshaft vibration damper. stage 2 85 85
Flywheel 87 64
Clutch pressure plate 24 18
Oil pump chain tensioner arm 12 9
Oil pump sprocket 18 13
Cylinder Head  
Cylinder head. stage 1 10 7
Cylinder head. stage 2 35 26
Cylinder head. stage 3 90 90
Cylinder head. stage 4 90 90
Cylinder head cover. stage 1 3 2
Cylinder head cover. stage 2 9 7
Auxiliary cylinder head bolts (x3) 38 28
Upper timing case 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
Blanking cover for rear coolant outlet 20 15
Spark plugs 18 13
Ignition coils 10 7

 

 

 

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