Engine Data - Zetec-E | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | | Engine management | EEC V/SEFI | EEC V/SEFI | EEC V/SEFI | | Engine code | L1N/L1Q | RKF/RKH | NGB/NGC | | Emission standard | EC Stage llE4 | EC Stage llE4 | D3/E4 | | Fuel | Premium 95 RON unleaded | Premium 95 RON unleaded | Premium 95 RON unleaded | | Firing order | 1-3-4-2 | 1-3-4-2 | 1-3-4-2 | | Bore (mm) | 76,0 | 80,6 | 84,8 | | Stroke (mm) | 88,0 | 88,0 | 88,0 | | Cubic capacity (cm 3) | 1.598 | 1.796 | 1.989 | | Compression ratio | 10,3:1 | 10,0:1 | 10,0:1 | | Engine power output (ISO) (kW) | 66 | 85 | 96 | | Engine power output at (rev/min) | 5.250 | 5.750 | 6.000 | | Torque (ISO) (Nm) | 138 | 158 | 180 | | Torque at (rev/min) | 3.500 | 3.750 | 4.000 | | Idle speed (rev/min) | 830 | 800 | 800 | | Engine speed limit (rev/min) | 7.100 | 7.100 | 7.100 | Engine oil - Zetec/Zetec-E | Type | Viscosity/ambient temperature | Specification | | Recommended engine oil | | | | Ford Formula E Economy Motor Oil | SAE 5W-30 / from -20 °C to over +40 °C | WSS-M2C913-A or WSS-M2C912-A1 | | Alternative engine oils | | | | Ford Super Multigrade Engine Oil | SAE 10W-30 / -20 °C to over +40 °C | ACEA A1/B1, A2/B2 or A3/B3 | | Ford XR+ High Performance High Lubricity Engine Oil | SAE 10W-40 / -20 °C to over +40 °C | ACEA A3, B3 | | Ford Formula S Synthetic Engine Oil | SAE 5W-40 / under -20 °C to over + 40 °C | ACEA A3, B3 | If these engine oils are not available, only engine oils which comply with the minimum API SH/EC (Energy Conserving) specification must be used. Capacities | | Litres | | Engine oil, initial fill incl. filter | 4,50 | | Engine oil, oil change incl. filter | 4,25 | | Engine oil, oil change excl. filter | 3,75 | | Coolant (with manual/ automatic transmission) | 6,6/7,1 | | Transmission fluid (MTX 75) | 1,9 | | Transmission fluid (iB5) | 2,3 | | Transmission fluid (CD4E with oil cooler) * = new transmissions are already filled with 3,5 liters of fluid. | 8,5* | Lubricants, Fluids, Sealers and Adhesives | Item | Specification | | Transmission fluid (MTX 75) | ESDM-2C186-A | | Transmission fluid (CD4E) | ESP-M2C166-H | | Sealer, camshaft bearing cap | WSK-M2G348-A5 | | Sealer for cylinder block mating face intersections | WSE-M4G323-A4 | | Lubricant (spark plug threads - Never Seeze) | ESE-M1244-A | | Thread-locking compound | SDM-M4G9107-A | | Silicone grease, spark plug connector seal | A696-M1C171-AA | Dimensions - cylinder block | | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | | Number of main bearings | | 5 | 5 | 5 | | Cylinder bore dia., class 1. | mm | 76,000 - 76,010 | 80,600 - 80,610 | 84,800 - 84,810 | | Cylinder bore dia., class 2. | mm | 76,010 - 76,020 | 80,610 - 80,620 | 84,810 - 84,820 | | Cylinder bore dia., class 3. | mm | 76,020 - 76,030 | 80,620 - 80,630 | 84,820 - 84,830 | | Inside dia. - main bearing shells (fitted) | mm | 58,011 - 58,038 | 58,011 - 58,038 | 58,011 - 58,038 | | Inside dia. - main bearing shells (fitted) (main bearing shells graded by size) | mm | 58,008 - 58,031 | 58,008 - 58,031 | 58,008 - 58,031 | | Main bearing radial clearances | mm | 0,011 - 0,058 | 0,011 - 0,058 | 0,011 - 0,058 | | Main bearing radial clearances (main bearing shells graded by size) | mm | 0,020 - 0,042 | 0,020 - 0,042 | 0,020 - 0,042 | | Main bearing parent bore | mm | 62,287 - 62,300 | 62,287 - 62,300 | 62,287 - 62,300 | Dimensions - crankshaft | | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | | Main bearing journal dia. | mm | 57,980 - 58,000 | 57,980 - 58,000 | 57,980 - 58,000 | | Main bearing journal end float | mm | 0,09 - 0,26 | 0,09 - 0,26 | 0,09 - 0,26 | | Big-end bearing journal dia. | mm | 46,89 - 46,91 | 46,89 - 46,91 | 46,89 - 46,91 | Dimensions - connecting rod | | | | | Bore diameter, big end | mm | 49,89 - 49,91 | | Bore diameter, small end | mm | 18,958 - 18,982 | | Inside dia. - big-end bearing shells (fitted) | mm | 46,926 - 46,960 | | Big-end bearing/rod bearing radial clearance | mm | 0,016 - 0,070 | | Big-end bearing clearance (axial) | mm | 0,090 - 0,320 | Dimensions - pistons (when new) | | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | | Piston dia., class 1. | mm | 75,975 - 75,985 | 80,580 - 80,610 | 84,780 - 84,810 | | Piston dia., class 2. | mm | 75,985 - 75,995 | 80,590 - 80,620 | 84,790 - 84,820 | | Piston dia., class 3. | mm | 75,995 - 76,005 | 80,600 - 80,630 | 84,800 - 84,830 | | Piston clearance in cylinder | mm | 0,040 - 0,060 | -0,010 - 0,030 | -0,010 - 0,030 | | Piston ring gaps (fitted) | | | | | | Upper compression ring | mm | 0,30 - 0,50 | 0,25 - 0,36 | 0,22 - 0,37 | | Lower compression ring | mm | 0,30 - 0,50 | 0,70 - 0,9 | 0,70 - 0,9 | | Oil scraper ring | mm | 0,25 - 1,00 | 0,38 - 1,14 | 0,20 - 0,70 | Dimensions - piston pin | | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | | Piston pin length | mm | | 49,85 - 50,15 | 54,70 - 55,00 | | Piston pin diameter | mm | | 18,997 - 19,000 | 18,995 - 19,000 | | Piston pin clearance in piston | mm | 0,010 - 0,017 | 0,010 - 0,017 | 0,010 - 0,016 | Dimensions - camshaft | | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | | Number of camshaft bearings | | 5 | 5 | 5 | | Drive | | Timing belt | Timing belt | Timing belt | | Bearing journal dia. | mm | 25,960 - 25,980 | 25,960 - 25,980 | 25,960 - 25,980 | | Camshaft bearing radial clearance | mm | 0,020 - 0,070 | 0,020 - 0,070 | 0,020 - 0,070 | | Camshaft end float | mm | 0,080 - 0,220 | 0,080 - 0,220 | 0,080 - 0,220 | Dimensions - valve | | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | | Valve clearance in valve guide | | | | | | Injector | mm | 0,017 - 0,064 | 0,017 - 0,064 | 0,017 - 0,064 | | - exhaust valve | mm | 0,017 - 0,064 | 0,017 - 0,064 | 0,017 - 0,064 | Valves | Description | | Petrol engine | Liquid propane gas (LPG) drive | | Valve control | | | Bucket tappets | | Valve clearance (engine cold); intake | mm | 0,11 - 0,18 | 0,07 - 0,22 | | Valve clearance (engine cold); exhaust | mm | 0,27 - 0,34 | 0,23 - 0,38 | Dimensions - cylinder head | | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | | Maximum distortion (mating face) | mm | 0,1 | 0,1 | 0,1 | | Mating face height | mm | 2,0 +0,12 - 0,24 | 2,0 +0,12 - 0,24 | 2,0 +0,12 - 0,24 | | Mating face peak-to-valley height (reference length 2,5 mm at right angles to direction of grooves) | µm | R 3z= 6,0 | R 3z= 6,0 | R 3z= 6,0 | | Oil pressure, at 800 - 850 rev/min | bar | 1,3 - 2,5 | 1,3 - 2,5 | 1,3 - 2,5 | | Oil pressure, at 4000 rev/min | bar | 3,7 - 5,5 | 3,7 - 5,5 | 3,7 - 5,5 | On the 2,0l engine the piston cooling oil nozzles are fully opened at 4000 rev/min. This produces a pressure loss of 0,3 - 0,8 bar, which may cause the 2,0l engine to go into the lower pressure range. Torque Specifications | Description | Nm | lb-ft | lb-in | | Hose clamps | 4 | | 35 | | Intake system | | | | | Intake manifold studs | 5 | | 44 | | Intake manifold bolts and nuts | 18 | 13 | | | Throttle body | 9 | | 80 | | EGR valve to intake manifold | 9 | | 80 | | Exhaust system | | | | | Heat shield to cylinder head (2,0 engine) | 10 | | 89 | | Heat shield and coolant pipe bracket to exhaust manifold (1,6 - 1,8l engine) | 10 | | 89 | | Heat shield and coolant pipe bracket to exhaust manifold (1,6 - 1,8l engine) | 23 | 17 | | | Exhaust manifold studs | 6 | | 53 | | Exhaust manifold nuts | 16 | 12 | | | Catalytic converter to exhaust manifold | 40 | 30 | | | EGR pipe to EGR valve | 29 | 21 | | | Bracket - EGR pipe to ignition coil | 6 | | 53 | | EGR pipe to exhaust manifold | 29 | 21 | | | Driveshafts | | | | | Center bearing - right-hand front driveshaft | 27 | 20 | | | Front driveshaft bracket to engine | 48 | 35 | | | Generator | | | | | Generator to bracket | 50 | 37 | | | Generator bracket to cylinder block | 47 | 35 | | | Transmission | | | | | Transmission/engine flange bolts | 40 | 30 | | | Starter motor to transmission | 48 | 35 | | | Transmission oil drain plug | 35 | 26 | | | Transmission oil check plug | 35 | 26 | | | Flywheel/drive plate | 112 | 83 | | | Clutch pressure plate | 29 | 21 | | | Subframe | | | | | Subframe to body | 130 | 96 | | | Steering gear to subframe | 130 | 96 | | | Radiator bracket to subframe | 10 | | 89 | | Air conditioning system | | | | | Air conditioning compressor to bracket | 25 | 18 | | | Engine mounting | | | | | Right-hand engine roll restrictor to transmission | 84 | 62 | | | Right-hand engine roll restrictor to subframe | 48 | 35 | | | Right-hand engine roll restrictor bracket to transmission (MTX 75) | 84 | 62 | | | Left-hand engine roll restrictor bracket to transmission (MTX 75) | 84 | 62 | | | Center bolt - left and right-hand engine roll restrictor | 120 | 89 | | | Rear engine mounting to transmission | 83 | 61 | | | Front engine mounting bracket to engine and engine mounting | 83 | 61 | | | Suspension | | | | | Hub nut | 290 | 214 | | | Wheel nuts | 85 | 63 | | | Suspension strut to body | 46 | 34 | | | Lower suspension arm ball joint to spindle carrier | 83 | 61 | | | Stabilizer link rod to suspension strut | 47 | 35 | | | Power steering | | | | | Power steering pump to bracket | 47 | 35 | | | A/C compressor bracket/power steering pump to cylinder block | 48 | 35 | | | Cylinder head | | | | | Camshaft position sensor to cylinder head | 21 | 15 | | | Cylinder head bolts, stage 1. | 15 | 11 | | | Cylinder head bolts, stage 2. | 40 | 30 | | | Cylinder head bolts, stage 3. | 90° | 90° | | | Camshaft bearing caps, stage 1. | 10 | | 89 | | Camshaft bearing caps, stage 2. | 19 | 14 | | | Cylinder head cover, stage 1. | 2 | | 18 | | Metal cylinder head cover, 2nd stage | 7 | | 62 | | Plastic cylinder head cover, 2nd stage | 9 | | 80 | | Spark plugs | 15 | 11 | | | Timing belt tensioner | 38 | 28 | | | Camshaft timing pulley | 68 | 50 | | | Upper timing belt cover | 10 | | 89 | | M10 x 11,5 oilway blanking plug | 24 | 18 | | | 1/4 P.T.F. oilway blanking plug | 25 | 18 | | | EI ignition coil bracket to cylinder head | 21 | 15 | | | Retaining plate for power steering pump to cylinder head | 47 | 35 | | | Thermostat housing | 20 | 15 | | | Engine lifting eye to cylinder head | 16 | 12 | | | Engine lifting eye to generator bracket | 47 | 35 | | | Bracket for oil dipstick tube | 9 | | 80 | | Cylinder block | | | | | Engine oil drain plug | 25 | 18 | | | Oil level indicator sensor | 22 | 16 | | | Oil pressure switch | 27 | 20 | | | Heater pipe bracket to oil pan | 10 | | 89 | | Oil pan | 21 | 15 | | | Oil pump | 11 | 8 | | | Piston cooling oil nozzles or blanking plugs | 10 | | 89 | | Oil intake pipe to oil pump | 10 | | 89 | | Oil baffle and oil intake pipe bracket to studs | 19 | 14 | | | Main bearing cap bolts and studs | 83 | 61 | | | Big-end bearing cap bolts, stage 1. | 15 | 11 | | | Big-end bearing cap bolts, stage 2. | 90° | 90° | | | Coolant pump | 18 | 13 | | | Crankshaft rear oil seal carrier | 30 | 22 | | | Multi-groove belt idler pulley | 48 | 35 | | | Bracket for positive crankcase ventilation pipe | 23 | 17 | | | Positive crankcase ventilation | 10 | | 89 | | Coolant pump belt pulley | 10 | | 89 | | Crankshaft belt pulley | 115 | 85 | | | Bracket of crankshaft position sensor | 21 | 15 | | | Crankshaft position sensor to bracket | 8 | | 71 | | |
