Engine Data | Description | | TCI diesel | | Engine management | | EEC V | | Emission standard | | 96 EC | | Fuel | | Diesel | | Engine code | | RFN | | Injection sequence | | 1-3-4-2 | | Bore | mm | 82,5 | | Stroke | mm | 82,0 | | Cubic capacity (effective) | cm 3 | 1753 | | Compression ratio | | 21,5 : 1 | | Compression pressure at starter motor speed | bar | 28-34 | | Engine power output (EEC) | kW | 66 | | Engine power output (EEC) at | rev/min | 4500 | | Torque (EEC) | Nm | 180 | | Torque (EEC) at | rev/min | 2250 | | Idle speed | rev/min | 850 - 860 | | Maximum engine speed - continuous | rev/min | 4500 | | Maximum engine speed - intermittent (without load) | rev/min | 5200 - 5300 | Lubricants, Fluids, Sealers and Adhesives | Item | Specification | | Coolant | ESD-M97B49-A | | Transmission fluid (MTX) | ESD-M2C168-A | | Power steering hydraulic fluid | ESPM-2C-166-H | | Sealer for camshaft bearing cap No. 1; oil pan to cylinder block | SPM-4G-9112-F/G | | Sealer for blanking plugs, oil pressure switch, oil passages | SM-4G-4644-AA/AB | | Sealer for coolant pump hose connections | SM-1C-1022-A | Engine oil up to 1999 MY | Viscosity / ambient temperature | Designation | Specification | | Recommended engine oil | | | | SAE10W-40 / -20°C to over +40°C | Ford XR+ High-performance High-lubricity Motor Oil | ACEA A3, B3 | | Alternative engine oil | | | | SAE 5W-40 / below -20°C to over +40°C | Ford Formula S Synthetic Motor Oil | ACEA A3, B3 | If engine oils of this specification are not available, only use engine oils which conform to specifications API SH/CD EC (energy conserving) and CCMC PD2 or better. Engine oil from 1999 MY | Ambient temperature/viscosity | Type | Specification | | Recommended engine oil | | | | SAE 10W-40 / -20°C to over +40°C | Ford Formula E Motor Oil | WSS-M2C912-A1 or WSS-M2C913-A | | Alternative engine oil | | | | SAE 5W-40 / below -20°C to over +40°C | Ford Formula S Synthetic Motor Oil | ACEA A3, B3 | | SAE 10W-40 / -20°C to over +40°C | Ford XR+ High-performance High-lubricity Motor Oil | ACEA A3, B3 | If engine oils of this specification are not available, only use engine oils which conform to specifications API SH/CD EC (energy conserving) and CCMC PD2 or better. Capacities | | Litres | | Engine oil, initial fill | 5,2 | | Engine oil change, incl. change of oil filter | 5,1 | | Engine oil, oil change without change of oil filter | 4,5 | | Coolant | 9,3 | | Transmission fluid (MTX 75) | 2,6 | Drivebelt Tension | Description | mm | | Generator (new) | 1-2 | | Generator (used) | 1-3 | | Power steering (new) | 1-2 | | Power steering (used) | 1-3 | | Air conditioning compressor (new) | 1-3 | | Air conditioning compressor (used) | 2-4 | Dimensions | Cylinder block | | TCI diesel | | Number of main bearings | | 5 | | Cylinder bore diameter, class A | mm | 82,500-82,515 | | Cylinder bore diameter, class B | mm | 82,515-82,530 | | Cylinder bore diameter, class C | mm | 82,660-82,675 | | Cylinder bore diameter, class D | mm | 82,675-82,690 | | Main bearing radial clearance | mm | 0,015-0,062 | | Main bearing parent bore dia. | mm | 57,683-57,696 | Dimensions | Crankshaft | | TCI diesel | | Main bearing journal diameter, standard | mm | 53,970-53,990 | | Main bearing journal diameter, 1st undersize 0,25 | mm | 53,720-53,740 | | Main bearing journal diameter, 2nd undersize 0,50 | mm | 53,470-53,490 | | Big-end bearing journal diameter, standard | mm | 48,970-48,990 | | Big-end bearing journal diameter, 1st undersize 0,25 | mm | 48,720-48,740 | | Big-end bearing journal diameter, 2nd undersize 0,50 | mm | 48,470-48,490 | | Big-end bearing clearance | mm | 0,025-0,085 | | Crankshaft end float | mm | 0,11-0,37 | Dimensions | Connecting rods | | TCI diesel | | Bore diameter, big end | mm | 52,000-52,020 | | Bore diameter, small end | mm | 26,012-26,020 | | Distance between connecting rod small and big ends, class A | mm | 129,872-129,948 | | Distance between connecting rod small and big ends, class B | mm | 129,932-130,008 | | Distance between connecting rod small and big ends, class C | mm | 129,992-130,068 | | Distance between connecting rod small and big ends, class D | mm | 130,052-130,128 | | Big-end bearing radial clearance | mm | 0,016-0,074 | Dimensions | Pistons | | TCI diesel | | Piston diameter (measured at right angles to piston pin bore), class A | mm | 82,463-82,477 | | Piston diameter (measured at right angles to piston pin bore), class B | mm | 82,478-82,492 | | Piston diameter (measured at right angles to piston pin bore), class C | mm | 82,622-82,639 | | Piston diameter (measured at right angles to piston pin bore) class E | mm | 82,963-82,977 | | Piston diameter (measured at right angles to piston pin bore), class F | mm | 83,463-83,477 | | Piston clearance (initial installation), classes A-F | mm | 0,021-0,054 | | Piston protrusion at TDC | mm | 0,500-0,840 | | Piston ring gap (fitted), upper compression ring | mm | 0,310-0,500 | | Piston ring gap (fitted), lower compression ring | mm | 0,310-0,500 | | Piston ring gap (fitted), oil control ring | mm | 0,250-0,580 | | Piston ring clearance in piston groove, upper compression ring | mm | 0,090-0,122 | | Piston ring clearance in piston groove, lower compression ring | mm | 0,070-0,102 | | Piston ring clearance in piston groove, oil control ring | mm | 0,050-0,082 | | Ring gap position | | The piston ring gaps must be distributed evenly around the circumference of the piston. This also applies to the elements of the oil scraper ring. Offset the gaps by 120 degrees to each other. | | Dimensions - piston pin | | TCI diesel | | Piston pin diameter | mm | 25,996-26,000 | | Piston pin type | | Floating fit in piston and connecting rod | | Piston pin retention | | Snap-ring | Dimensions | Cylinder head | | TCI diesel | | Camshaft bearing diameter, standard | mm | 30,500-30,525 | | Camshaft bearing diameter, oversize | mm | 30,575-30,600 | | Valve tappet bore diameter, standard | mm | 35,000-35,030 | | Valve tappet bore diameter, oversize | mm | 35,500-35,530 | | Valve guide bore diameter, standard | mm | 8,000-8,025 | | Valve guide bore diameter, 1st oversize | mm | 8,263-8,288 | | Valve guide bore diameter, 2nd oversize | mm | 8,463-8,488 | | Thickness of cylinder head gasket with piston protrusion of 0,500 - 0,680 mm | mm | 1,36 (two tooth marks) | | Thickness of cylinder head gasket with piston protrusion of 0,681 - 0,740 mm | mm | 1,42 (three tooth marks) | | Thickness of cylinder head gasket with piston protrusion of 0,741 - 0,840 mm | mm | 1,52 (four tooth marks) | | Max. permissible unevenness over entire head mating face | mm | 0,08 | Dimensions | Camshaft | | TCI diesel | | Valve timing, inlet valve opens before TDC | °CS | 6 | | Valve timings, inlet valve closes after BDC | °CS | 32 | | Valve timings, exhaust valve opens before BDC | °CS | 57 | | Valve timings, exhaust valve closes after TDC | °CS | 7 | | Cam lift, inlet | mm | 8,99 | | Cam lift, exhaust | mm | 10,0 | | End float | mm | 0,100-0,240 | | Bearing journal diameter | mm | 27,9995 - 28,055 | | Bearing clearance | mm | 0,016-0,075 | | Valve clearance (cold), inlet | mm | 0,30-0,40 | | Valve clearance (cold), exhaust | mm | 0,45-0,55 | | Thickness of valve adjustment shims | mm | 3,00-4,75 | | Thickness of valve adjustment shims, in steps of | mm | 0,05 | Dimensions | Engine lubrication | | TCI diesel | | Oil pressure (minimum, oil temperature approx. 80° C), with engine idling | bar | 0,75 | | Oil pressure (minimum, oil temperature approx. 80° C), at 2000 1/min | bar | 1,50 | | Pressure relief valve opening pressure | bar | 2,0-4,0 | | Oil pump, max. clearance between inner/outer rotors | mm | 0,174 | Torque Specifications | Description | Nm | lb-ft | lb-in | | Wheel nuts | 85 | 63 | | | Axle nuts | 290 | 214 | | | Bumper reinforcement strut | 10 | | 89 | | Lower suspension arm ball joint to spindle carrier | 83 | 61 | | | Tie-rod end to spindle carrier | 26 | 19 | | | Stabiliser bar link rod to suspension strut | 47 | 35 | | | Center bearing of front driveshaft to bracket | 27 | 20 | | | Center bearing bracket to cylinder block | 48 | 35 | | | Bracket of front engine mounting to engine mounting | 83 | 61 | | | Bracket of front engine mounting to engine bracket | 83 | 61 | | | Engine mounting to body | 83 | 61 | | | Wiring loom bracket to transmission | 12 | 9 | | | Subframe to body | 130 | 96 | | | Bracket of rear engine roll restrictor to subframe | 48 | 35 | | | Center bolt of rear engine roll restrictor | 120 | 89 | | | Bracket of rear engine roll restrictor to transmission | 84 | 62 | | | Bracket of front engine roll restrictor to transmission | 84 | 62 | | | Bracket of front engine roll restrictor to subframe | 48 | 35 | | | Center bolt of front engine roll restrictor | 120 | 89 | | | Coolant drain plug | 23 | 17 | | | Radiator to subframe | 10 | | 89 | | Coolant pump | 23 | 17 | | | Thermostat housing | 20 | 15 | | | Vacuum line bracket to thermostat housing | 9 | | 80 | | Air conditioning dehydrator | 7 | | 62 | | Air conditioning compressor to bracket | 25 | 18 | | | Condenser to radiator | 7 | | 62 | | Intercooler to bracket | 18 | 13 | | | Turbocharger bracket to cylinder block | 24 | 18 | | | Bracket of power steering line to body | 10 | | 89 | | Power steering drivebelt cover | 10 | | 89 | | Power steering pump to bracket | 24 | 18 | | | Power steering drivebelt tensioner to timing cover | 23 | 17 | | | Power steering drivebelt tensioner to power steering pump bracket | 24 | 18 | | | Power steering line bracket to subframe | 12 | 9 | | | Steering gear to subframe | 130 | 96 | | | Power steering pump belt cover | 10 | | 89 | | Engine mounting/power steering pump bracket to cylinder block | 47 | 35 | | | Engine lifting eye to engine mounting/power steering pump bracket | 23 | 17 | | | Exhaust manifold to catalytic converter | 40 | 30 | | | Catalytic converter to exhaust system | 40 | 30 | | | Catalytic converter to bracket | 24 | 18 | | | Vacuum line to vacuum pump | 16 | 12 | | | Vacuum pump to cylinder head | 22 | 16 | | | Transmission flange bolts | 40 | 30 | | | Starter motor to engine | 20 | 15 | | | Starter motor bracket to engine | 20 | 15 | | | Wiring to glow plugs | 3 | | 27 | | Glow plugs | 20 | 15 | | | Wiring loom bracket to lifting eye | 23 | 17 | | | Fuel filter to bracket | 23 | 17 | | | Oil pressure switch to cylinder head | 20 | 15 | | | Engine oil drain plug | 25 | 18 | | | Oil intake pipe bracket to cylinder block | 22 | 16 | | | Oil pan | 11 | 8 | | | Clip of turbocharger oil return hose | 5 | | 44 | | Oil dipstick tube | 10 | | 89 | | Main bearing caps, stage 1 | 27 | 20 | | | Main bearing caps, stage 2 | 75° | 75° | | | Big-end bearing caps, stage 1 | 25 | 18 | | | Big-end bearing caps, stage 2 | 60° | 60° | | | Big-end bearing caps, stage 3 | 20° | 20° | | | Timing cover to cylinder block | 24 | 18 | | | Crankshaft rear oil seal carrier | 20 | 15 | | | Flywheel, stage 1 | 18 | 13 | | | Flywheel, stage 2 | 45° | 45° | | | Flywheel, stage 3 | 45° | 45° | | | Clutch pressure plate to flywheel | 30 | 22 | | | Crankshaft position sensor bracket | 21 | 15 | | | Auxiliary shaft thrust plate | 9 | | 80 | | Auxiliary shaft oil seal carrier | 23 | 17 | | | Generator bracket to cylinder block | 42 | 31 | | | Generator to bracket (M8) | 24 | 18 | | | Generator to bracket (M10) | 50 | 37 | | | Tensioning pulley bracket to generator bracket | 24 | 18 | | | Bolt of generator tensioning pulley | 24 | 18 | | | Cylinder head bolts, stage 1 | 10 | | 89 | | Cylinder head bolts, stage 2 | 100 | 74 | | | Cylinder head bolts, stage 3 (wait three minutes first) | -180° | -180° | | | Cylinder head bolts, stage 4 | 70 | 52 | | | Cylinder head bolts, stage 5 | 120° | 120° | | | Vacuum line bracket to cylinder head | 22 | 16 | | | Camshaft oil baffle | 20 | 15 | | | Camshaft bearing caps | 23 | 17 | | | Cylinder head cover | 5 | | 44 | | Injectors | 95 | 70 | | | Fuel-injection pump to timing cover | 24 | 18 | | | Fuel-injection pump bracket to cylinder block | 23 | 17 | | | Fuel filter bracket to cylinder head | 23 | 17 | | | Fuel-injection lines to injectors | 25 | 18 | | | Fuel-injection lines to fuel-injection pump | 25 | 18 | | | Fuel-injection pump pulley | 25 | 18 | | | Adjusting cam to cylinder head | 45 | 33 | | | Camshaft timing belt pulley to camshaft (M8) | 35 | 26 | | | Camshaft timing belt pulley to camshaft (M10) | 48 | 35 | | | Camshaft timing belt tensioner to cylinder head (M8) | 10 | | 89 | | Camshaft timing belt tensioner to cylinder head (M12) | 50 | 37 | | | Rear timing belt cover to cylinder block | 24 | 18 | | | Auxiliary shaft timing pulley | 45 | 33 | | | Fuel-injection pump timing pulley to flange | 23 | 17 | | | Fuel-injection pump timing belt tensioner to cylinder block | 45 | 33 | | | Blanking plug - TDC setting | 24 | 18 | | | Pulley/vibration damper flange bolt to crankshaft, stage 1 (degrees) | 150 | 111 | | | Pulley/vibration damper flange bolt to crankshaft, stage 2 | -90° | -90° | | | Pulley/vibration damper flange bolt to crankshaft, stage 3 | 120 | 89 | | | Vibration damper flange to crankshaft, stage 4 | 60° | 60° | | | Oil feed pipe - turbocharger | 18 | 13 | | | Bracket of turbocharger oil feed pipe | 23 | 17 | | | Catalytic converter bracket | 24 | 18 | | | Bracket for glow plug power supply | 10 | | 89 | | Covers - timing belt | 8 | | 71 | | Coolant pipe bracket | 25 | 18 | | | Oil pump to cylinder block | 23 | 17 | | | Intake manifold to cylinder head | 23 | 17 | | | Exhaust to cylinder head | 23 | 17 | | | Coolant recovery tank | 10 | | 89 | | Oil return pipe to vacuum pump | 16 | 12 | | | Wheel arch trim panel | 11 | 8 | | | EGR pipe | 15 | 11 | | | Air cleaner bracket | 23 | 17 | | | Pulley/vibration damper to vibration damper flange | 35 | 26 | | | |
