Last update:

08/03/2005

Engine Data 2.5 TD

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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


Block

Camshaft

Crankshaft

Pulleys

Inlet

Inlet

Sump

Timing Gear

Turbo
     

Engine management

EDC

Emission standard

94 EEC/12

Fuel

Diesel

Engine code

SCD

Injection sequence

1-3-4-2

Bore mm

92

Stroke mm

94

Cubic capacity effective

2498 cc

Compression ratio

20.2 - 21.7 : 1

Compression pressure at starter motor speed

bar 24 - 26

Power output (EEC)

kW 92

Power output (EEC) at rev/min

4200

Power output (DIN)

kW 92

Power output (DIN)

PS 125

Power output (DIN) at rev/min

4200

Torque (EEC/DIN)

Nm 293

Torque (EEC/DIN) at rev/min

2000

Idle speed rev/min

875 50

Continuous engine speed rev/min

4200

Maximum engine speed rev/min

4750

 

Dimensions

Cylinder block and main bearing housings

mm

Number of main bearings

5

Main bearing inside . front. standard

63.043 - 63.088

Main bearing inside . front. 1st undersize 0.25

62.793 - 62.838

Main bearing inside . front. 2nd undersize 0.50

62.543 - 62.588

Main bearing shell width. front

31.750 - 32.250

Main bearing clearance (radial). front

0.043 - 0.103

Front main bearing. depth from front face

6

Main bearing inside - main bearing housing. standard

63.050 - 63.093

Main bearing inside - main bearing housing. 1st Undersize 0.25

62.800 - 62.843

Main bearing inside - main bearing housing. 2nd undersize 0.50

62.550 - 62.593

Main bearing shell width - main bearing housing

29.750 - 30.000

Main bearing clearance (radial) - main bearing housing

0.030 - 0.073

Main bearing inside . rear. standard

70.050 - 70.065

Main bearing inside . rear. 1st undersize 0.25

69.800 - 69.815

Main bearing inside . rear. 2nd undersize 0.50

69.550 - 69.565

Main bearing shell width. rear

31.750 - 32.250

Main bearing clearance (radial). rear

0.050 - 0.085

Camshaft bearing inside . front

53.540 - 53.590

Camshaft bearing inside . centre

53.540 - 53.590

Camshaft bearing inside . rear

53.540 - 53.590

Camshaft bearing clearance (radial)

0.030 - 0.095


 

Cylinder liners

mm

Cylinder liner . class A

92.000 - 92.010

Cylinder liner protrusion

0.00 - 0.05

Thickness of shims

0.15 / 0.17 / 0.20 / 0.23 / 0.25


 

Crankshaft

mm

Main bearing journal . front. standard

62.985 - 63.000

Main bearing journal . front. 1st undersize 0.25

62.735 - 62.750

Main bearing journal . front. 2nd undersize 0.50

62.485 - 62.500

Main bearing journal - main bearing housing. Standard

63.005 - 63.020

Main bearing journal - main bearing housing. 1st undersize 0.25

62.755 - 62.770

Main bearing journal - main bearing housing. 2nd undersize 0.50

62.505 - 62.520

Main bearing journal . rear. standard

79.980 - 80.000

Main bearing journal . rear. 1st undersize 0.25

79.730 - 79.750

Main bearing journal . rear. 2nd undersize 0.50

79.480 - 79.500

Big-end bearing journal . standard

53.940 - 53.955

Big-end bearing journal . 1st undersize 0.25

53.690 - 53.705

Big-end bearing journal . 2nd undersize 0.50

53.440 - 53.440

Crankshaft end float

0.08 - 0.23

Thickness of thrust washers. standard

2.311 - 2.362

Thickness of thrust washers. 1st oversize

2.411 - 2.462

Thickness of thrust washers. 2nd oversize

2.511 - 2.562

Connecting rod bearing inside . big-end - standard

53.977 - 54.016

Connecting rod bearing inside . big-end - 1st

undersize 0.25

53.727 - 53.766

Connecting rod bearing inside . big-end - 2nd

undersize 0.25

53.477 - 53.516

Bearing shell width

22.750 - 23.250

Connecting rod bearing clearance (radial). big-end

0.022 - 0.076

Bearing inner . small end

30.035 - 30.050


 

Pistons

mm

Piston (measured at right-angles to the piston pin bore). class A

91.935 - 91.945

Piston (measured at right-angles to the piston pin bore). class B

91.945 - 91.955

Piston clearance (initial installation). class A

0.055 - 0.075

Piston protrusion at TDC

0.530 - 0.820

Piston ring gap (fitted). upper compression ring

0.25 - 0.50

Piston ring gap (fitted). lower compression ring

0.20 - 0.35

Piston ring gap (fitted). oil control ring

0.25 - 0.58

Piston ring clearance in piston groove. upper compression ring

0.080 - 0.130

Piston ring clearance in piston groove. lower compression ring

0.070 - 0.102

Piston ring clearance in piston groove. oil control ring

0.040 - 0.072

Ring gap positions: the piston ring gaps must be evenly distributed around the circumference of the piston. This also applies to the elements of the oil control ring. Stagger the ring gaps at intervals of 120.

Piston pin type

"Floating" in piston
and connecting rod

Piston pin retention

Circlips

Piston pin . class A

29.990 - 29.993

Piston pin . class B

29.993 - 29.996

Piston pin clearance (radial). class A

0.039 - 0.042

Piston pin clearance (radial). class B

0.057 - 0.060


 

Cylinder head

mm

Number of cylinder heads

4

Height of cylinder heads

89.950 - 90.050

Height of end spacers

89.92 - 90.000

Thickness of cylinder head gasket with piston
(Number of notch marks)
protrusion of 0.53 - 0.62 mm

.42 (0)

Thickness of cylinder head gasket with piston protrusion of 0.63 - 0.72 mm

1.52 (2)

Thickness of cylinder head gasket with piston protrusion of 0.73 - 0.82 mm

1.62 (1)


 

Camshaft

mm

Valve timings - inlet opens BTDC

26 C/S

Valve timings - exhaust closes ATDC

36 C/S

Cam lift (camshaft) - inlet

7.019

Cam lift (camshaft) - exhaust

7.303

Thickness of thrust plate

3.950 - 4.050

Camshaft end float

0.050 - 0.200

Bearing journal . front

53.495 - 53.510

Bearing journal . centre

53.450 - 53.470

Bearing journal . rear

53.480 - 53.500

Bearing journal . 1st undersize 0.25 mm

53.245 - 53.260


 

Engine Oil

Viscosity / Ambient temperature

Recommended engine oil:

Specification

SAE 15W40 / -15 to over 40C

Ford Super Multigrade
Engine Oil

ACEA A2-96/B2-96 or
A3-96/B3-96 or
API/SH/CD EC

Alternative engine oils:

SAE 5W40 / below -20 to over 40C Ford Formula S
Synthetic Engine Oil
ACEA A3-96/B3-96 or
API/SH/CD EC
SAE 10W40 / -20 to over 40C Ford XR + High-performance High-Lubricity Engine Oil
ACEA A3-96/B3-96 or
API/SH/CD EC

Only for diesel engines: if engine oils with these specifications are not available. only use engine oils which conform to specification API/SH/CD EC and CCMC PD2 or better.


Engine Lubrication


bar

Oil pressure (minimum) . at idle speed

1.5

Oil pressure (oil temperature approx. 100C) at 4000 rev/min

4.0

Pressure relief valve opening pressure

6.38


 

Lubricants. Adhesives and Sealers

Description

Ford Specification

Coolant

ESD-M97B-49A

Transmission fluid (MT 75)

ESD-M2C186-A

Lubricant - cylinder liner (bottom). connecting rod bolts. crankshaft rear oil seal.

SAE 15W40 API

hydraulic tappets

SG/CD (engine oil)

Lubricant for main and camshaft bearings. big-end bearings. oil pump spigot. vacuum pump spigot. timing gears

SQM-2C-9002-AA

Hypoid oil

SAE90

Lubricant for M12 cylinder head bolts

SAE 15W40 - API SG/CD (engine oil)

Lubricant for M14 cylinder head bolts

SQM-2C-9002-AA Hypoid oil SAE90

Lubricant for O-rings. crankshaft thrust washers

ESD-M1C220-A

Cylinder liner adhesive Loctite 277

WSK-M2G351-A7

Adhesive for oil dipstick tube. fuel injection pump studs. oilway blanking plugs. piston

WSK-M2G349-A1cooling nozzles

Adhesive for coolant temperature sensors. crankshaft pulley/vibration damper nut (Loctite 510)

WSK-M2G349-A7

Adhesive for pressure relief valve. cylinder block plugs

WSK-M2G348-A5

Sealer for sump

SLM-4G9111-A

Sealer for injectors

ESEAM-1C1014

Sealer - timing cover to engine block

SPM-2G9121-A

Ford hypoid oil

SQM-2C9002-AA


Capacity


Litres

Engine oil. initial fill with filter

7.3

Engine oil. incl. filter change

6.6

Engine oil. excl. filter change

6.0

Coolant

7.0


 

Timing Belt

Tension

Belt tension. new (N)

332 - 375

Setting of automatic belt tensioner (X)

85

Follow the instructions to adjust the belt tension.


 

Torques

General

Nm

lbf.ft

Hood hinge bolts

23

17

Front axle transverse brace to side members

80

59

Front axle/engine crossmember to side members. M12

80

59

Front axle/engine crossmember to side members. M10

47

35


Starter motor

Starter motor to transmission intermediate flange

35

26

Heat shield bracket to starter motor

12

9

Inlet and exhaust manifold

Inlet manifold to cylinder heads

32

24

Exhaust manifold to cylinder heads

32

24

Front exhaust pipe to turbocharger

45

33

Front to rear exhaust pipe

45

33


 

Fuel system

Gear to fuel injection pump

88

65

Injectors

69

51

Fuel injection pipes to injectors and fuel injection pump

17

13

Fuel return pipe to fuel injection pump

27

20


 

Alternator

Alternator bracket to cylinder block

47

35

Alternator to bracket - lower position

28

21

Alternator to bracket - upper position

47

35


 

Transmission

Transmission intermediate flange to engine (M8)

27

20

Transmission intermediate flange to engine (M10)

44

32

Transmission intermediate flange to sump

37

27

Transmission housing to transmission intermediate flange

44

32

Transmission mounting bracket

44

32

Starter motor to transmission intermediate flange

35

26


 

Coolant circuit

Radiator and intercooler to crossmember

23

17

Coolant collecting pipe to cylinder heads

12

9

Coolant pump to cylinder block

25

18

Coolant pipe bracket to cylinder block

27

20

Coolant expansion tank to engine

5

4


Steering

Steering intermediate shaft to steering shaft

24

18

Power steering pump pulley

31

23

Power steering pump to bracket

21

16


 

Oil circuit

Oil intake pipe bracket to cylinder block

27

20

Oil feed connection of main bearing housing in cylinder Block

47

35

Sump blanking plug

35

26

Oil pipes to extension of oil filter intermediate housing

33

24

Sump to cylinder block

12

9

Oil pump to cylinder block

27

20

Rocker arm oil feed pipe to cylinder heads

13

10

Oil pipe extension to cylinder block

25

18

Rocker arm oil feed pipe to connector

23

17

Oil feed pipe to hollow retaining screw in main bearing housing

33

24

Vacuum pump oil feed pipe

23

17

Bracket of vacuum pump oil feed pipe to cylinder block

27

20

Oil filter intermediate housing to cylinder block

60

44

Oil pressure switch

32

24


 

Turbocharger

Oil feed pipe to turbocharger

27

20

Heat shield to turbocharger. nuts

10

7

Heat shield to turbocharger. bolts

12

9


 

Vacuum pump

Vacuum pump to cylinder block

28

21

Vacuum pump connector to cylinder block

54

40


 

Engine mounting

Engine mounting to front axle/engine support bar

50

37

Right-hand engine mounting bracket to cylinder block

47

35

Left-hand engine mounting bracket to cylinder block

47

35


Cylinder block

Engine mounting bracket to cylinder block

47

35

Mounting bracket 21-031B to engine mounting bracket

47

35

Fix cylinder liners with clamps

30

22

Main bearing housings

42

31

Hollow retaining screws - main bearing housings to engine block

47

35

Big-end bearing caps. 1st stage

29

21

Big-end bearing caps. 2nd stage

605

446

Oil seal and main bearing housing to transmission intermediate flange

12

9

Camshaft thrust plate to cylinder block

29

21

Timing cover to cylinder block

12

9

Crankshaft pulley/vibration damper to crankshaft

196

145

Flywheel to crankshaft. 1st stage

20

15

Flywheel to crankshaft. 2nd stage

755

557

Clutch to flywheel

27

20

Fuel injection pump to cylinder block

30

22

Fuel filter retaining plate to cylinder block. M8

27

20

Fuel filter retaining plate to cylinder block. M10

47

35

Clamp bolt of automatic belt tensioner eccentric adjuster

47

35

Automatic belt tensioner bracket to cylinder block

69

51

Air conditioning compressor

25

18

Engine lifting eye

47

35

Crankshaft position sensor (CKP sensor) to transmission Intermediate flange

12

9


 

Cylinder heads

Glow plugs

14

10

Cylinder head bolts M14. inner. 1st stage

30

22

Cylinder head bolts M14. inner. 2nd stage

705

520

Cylinder head bolts M14. inner. 3rd stage

705

520

Cylinder head bolts M12. outer. 1st stage

30

22

Cylinder head bolts M12. outer. 2nd stage

855

631

Pipe flange to EGR valve

27

20

Rocker shaft to cylinder heads

27

20

Cylinder head cover

15

11


Retorque cylinder head bolts

Cylinder head bolts M14. inner. 1st stage

-1805 (undo)

-1805 (undo)

Cylinder head bolts M14. inner. 2nd stage

30

22

Cylinder head bolts M14. inner. 3rd stage

1305

1305

Cylinder head bolts M12. outer. 1st stage

90

66

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