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Engine Data – DOHC2300 16V
General
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 90ø to each other Cylinder head with valve seat inserts* Cast mark 2,3 Upper correction angle, inlet valve (production) ø 30 Upper correction angle, exhaust valve (production) ø 30 Valve seat angle ø 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) ø 75 Lower correction angle, exhaust (production) ø 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 øCS 9 Valve timing, inlet closes ABDC øCS 51 Valve timing, exhaust opens BBDC øCS 48 Valve timing, exhaust closes ATDC øCS 12 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
Oil pressure at 800 rpm
Oil pressure at 2000 rpm Pressure relief valve opens at bar 3,70 - 4,60 Oil control light comes on at bar 0,30 - 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 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
Lubricants, Adhesives and Sealers
Description
Ford Coolant ESD-M97B49-A Sealer, coolant temperature sensor, coolant pump angle connector, oil WSK-M2G349-A7 pressure switch (Loctite 243) 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 -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 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 90ø 90ø 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 90ø 90ø 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 85ø 85ø 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 90ø 90ø Cylinder head bolts, 4th stage 90ø 90ø 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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