| Specifications | Identification code | '95 model year | 4GA | | Identification code, vehicles up to 2,8 t | '95 model year | 4GC | | Identification code, LDT (light commercial vehicles) | '95 model year | 4GB | | Identification code, 2,5 TCI diesel engine | '97 model year | 4GD | | Identification code, LDT (light commercial vehicles) | '97 model year | 4GE | | Emission standard: 4GA | | A13 | | Emission standard: 4GC | | 93 EEC | | Emission standard: 4GB | | 95/97 EEC | | Emission standard: 4GD | | 96 EEC | | Emission standard: 4GE | | 97 EEC | | Injection sequence (cylinders numbered from front to rear) | | 1‐2‐4‐3 | | Bore | | 93,67 mm | | Stroke | | 90,54 mm | | Cubic capacity | | 2496 cc | | Compression ratio | | 19,0 : 1 | | Power output (EEC) | | 63 kW | | Power output (EEC) | | 85 PS | | Power output (EEC) | at rev/min | 4000 | | Torque (EEC) | | 200 Nm | | Torque (EEC) | at rev/min | 2100 | | Idle speed | | 850 ± 25 | | Max. permissible engine speed | Continuous rev/min | 4000 | | Maximum permissible engine speed | Intermittent rev/min | 4400 | | Bore diameter | Class 1. | 93,648 ‐ 93,660 | | Class 2. | 93,660 ‐ 93,672 | | Class 3. | 93,672 ‐ 93,684 | | Class 4. | 93,684 ‐ 93,696 | | Measuring point | 80 mm below cylinder head mating face | | Main bearing bore in the cylinder block ‐ rear | Class A | 81,00 ‐ 81,02 | | Class B | 81,40 ‐ 81,42 | | Main bearing bore in the cylinder block ‐ others | Class A | 74,00 ‐ 74,02 | | Class B | 74,40 ‐ 74,42 | | Camshaft bearing bore in cylinder block | Standard | 61,000 ‐ 61,046 | | Oversize | 61,500 ‐ 61,546 | | Pistons | | | | Number of piston rings | Compression rings | 2 | | Oil scraper ring | 1 | | Ring groove width | Upper compression ring | 2,13 ‐ 2,15 | | Lower compression ring | 2,070 ‐ 2,095 | | Oil scraper ring | 4,030 ‐ 4,055 | | Piston pin bore: | Orange | 29,002 ‐ 29,006 | | Black | 29,006 ‐ 29,010 | | Standard piston Ø | Class 1. | 93,621 ‐ 93,633 | | Class 2. | 93,633 ‐ 93,645 | | Class 3. | 93,645 ‐ 93,657 | | Class 4. | 93,657 ‐ 93,669 | | Piston clearance in bore | | 0,015 ‐ 0,039 | | Height of measuring point for piston clearance in bore, measured from the piston crown at right angles to the piston pin bore | | 81,5 | | Piston oversize | | 0,65 and 1,00 | | Piston protrusion relative to cylinder block face at TDC, in production | | 0,201 ‐ 0,403 | | Piston pins | | | | Outside dia. | Orange | 28,996 ‐ 29,000 | | Outside dia. | Black | 29,000 ‐ 29,004 | | Piston pin length | | 79,000 ‐ 79,400 | | Clearance in piston pin bore (selective fit) | | 0,002 ‐ 0,010 | | Piston rings | | | | Ring gaps: | Upper compression ring | 0,40 ‐ 0,65 | | Ring gaps: | Lower compression ring | 0,40 ‐ 0,65 | | Oil scraper ring | 0,25 ‐ 0,58 | | Upper compression ring | 0,25 ‐ 0,50 | | Lower compression ring | 0,25 ‐ 0,50 | | Oil scraper ring | 0,25 ‐ 0,58 | | Ring widths: | Upper compression ring | 2,313 ‐ 2,333 | | Lower compression ring | 1,975 ‐ 1,990 | | Oil scraper ring | 3,978 ‐ 3,990 | | Lateral clearance in grooves: | Upper compression ring | 0,14 ‐ 0,172 | | Lower compression ring | 0,06 ‐ 0,092 | | Oil scraper ring | 0,02 ‐ 0,052 | | Connecting rod length between bore centres: | 1A | 153,862 ‐ 153,931 | | 2A | 153,931 ‐ 154,000 | | 3A | 154,000 ‐ 154,069 | | 4A | 154,069 ‐ 154,138 | | Piston pin bush bore | | 29,010 ‐ 29,022 | | Piston pin clearance | | 0,006 ‐ 0,026 | | Big‐end bore without bearing shells | | 63,506 ‐ 63,520 | | Bearing shell oversizes | | 1,738 ‐ 1,729 | | Bearing shell thickness (standard) | | 0,125; 0,25; 0,375; 0,5 | | Bearing shell width | | 25,87 ‐ 26,13 | | Big‐end bearing clearance | | 0,030 ‐ 0,095 | | End float on big‐end bearing journal | | 0,140 ‐ 0,420 | | Max. ovality of big‐end bearing journal | | 0,025 | | Max. ovality of big‐end bearing journal | when already re‐worked | 0,010 | | Number of main bearing journals | | 5 | | Main bearing journal dia.: Rear | Size 1 mm | 76,980 ‐ 77,000 | | Size 2 mm | 76,730 ‐ 76,750 | | Main bearing journal dia.: Others | Size 1 mm | 69,980 ‐ 70,000 | | Size 2 mm | 69,730 ‐ 69,750 | | Regrind undersize (nominal, service diameter): ‐ Rear | Size 3 mm | 76,490 ‐ 76,500 | | Size 4 mm | 69,490 ‐ 69,500 | | Regrind undersize (nominal, service diameter): Others | Size 3 mm | 76,240 ‐ 76,250 | | Size 4 mm | 69,240 ‐ 69,250 | | Main bearing journal length (centre) | | 35,625 ‐ 35,675 | | Crankshaft end float | | 0,075 ‐ 0,325 | | Main bearing clearance: | Nos. 1 to 4 | 0,052 ‐ 0,090 | | No. 5 | 0,056 ‐ 0,094 | | Number of teeth on driving gear and timing belt pulley on crankshaft: | Oil pump driving gear | 32 teeth | | Timing belt pulley | 24 teeth | | Maximum turning torques: | Crankshaft on its own (without connecting rods and pistons) | 2,9 Nm | | Crankshaft (with rear oil seal, connecting rods and pistons; without cylinder head and timing cover) | 50 Nm | | Camshaft | Inlet | 7,3 | | Exhaust | 7,6 | | Number of bearings | | 5 | | Bearing journal diameter | | 55,966 ‐ 55,941 | | Bearing bore | | 56,032 ‐ 56,058 | | Bearing clearance | | 0,072 ‐ 0,116 | | Oversize bearings (outside diameter) | | 0,50 | | Camshaft end float | | 0,10 ‐ 0,25 | | Driving gear backlash | | 0,050 ‐ 0,330 | | Inner/outer rotor clearance | | 0,150 max. | | Outer rotor/housing clearance | | 0,13 ‐ 0,30 | | Rotor end float | | 0,01 ‐ 0,09 | | Oil pressure: | New engine (idle speed) | 1,0 bar | | Normal operation | 2,7 ‐ 4,8 bar | | Max. friction face run‐out | | 0,130 at radius of 120 | | Valve guide length ‐ inlet and exhaust | | 56,50 | | Valve guide dia. ‐ inlet and exhaust: | Outside dia. | 14,738 ‐ 14,725 | | Inside dia. | 8,982 ‐ 9,013 | | Valve guide protrusion relative to cylinder head cover mating face | | 1,80 ‐ 2,30 | | Valve seat rings (when fitted), recess dia.: | Inlet | 43,50 ‐ 43,54 | | Exhaust | 37,96 ‐ 38,00 | | Recess depth ‐ inlet and exhaust | | 9,00 ‐ 9,15 | | Valve seat angle relative to horizontal: | Inlet | 30° ‐ 30°30' | | Exhaust | 45° ‐ 45°30' | | Valve head depth in cylinder head: | Inlet | 0,35 ‐ 0,65 | | Exhaust | 0,50 ‐ 0,80 | | Recess dia. | Inlet | 43,50 max. | | Exhaust | 37,96 max. | | Depth (both) | 9,00 max. | | Valve head dia. | Inlet | 41,90 ‐ 42,10 | | Exhaust | 36,20 ‐ 36,40 | | Valve head seat angle: | Inlet | 29°30' ‐ 30° | | Exhaust | 44°30' ‐ 30° | | Stem dia. | Inlet | 8,941 ‐ 8,966 | | Exhaust | 8,923 ‐ 8,948 | | Stem clearance: | Inlet | 0,010 ‐ 0,066 | | Exhaust | 0,024 ‐ 0,084 | | Valve spring identification colour | Inlet | Red | | Exhaust | Green and yellow | | | | | Rocker shaft diameter | | 18,87 ‐ 18,90 | | Number of springs on rocker shaft | | 4 | | Spring length (compressed) | | 25,4 | | Spring force (compressed) | | 17 ‐ 21 N | | Rocker arm clearance on shaft | | 0,02 ‐ 0,08 | | Push rod length | | 154,87 ‐ 153,87 | | Push rod dia. | | 7,72 ‐ 8,03 | | Tappet stem dia. | | 17,475 ‐ 17,488 | | | 66,10 ‐ 66,85 | | Nominal valve timings with clearance of 0,5 mm: | Inlet valve opens | 5° before TDC | | Inlet valve closes | 27° after BDC | | Exhaust valve opens | 57° before TDC | | Exhaust valve closes | 7° after TDC | | Valve lift: | Inlet | 9,12 | | Exhaust | 10,81 | | Valve clearance (warm or cold): | Inlet | 0,20 | | Exhaust | 0,38 | | New belt | Belt tension: | 578 ‐ 423 N | | Deflection: | 4,5 mm | | New belt after 15 minutes' running | Belt tension: | 378 ‐ 423 N | | Deflection: | 5,5 mm | | Used belt (used for less than 10 minutes) | | 378 ‐ 423 N | | Paint mark at three points | | Green | | New belt | | 578 ‐ 623 | | New belt after 15 minutes' running | | 378 ‐ 423 | | Used belt | | 378 ‐ 423 | | Paint mark at three points | | Green | Main bearing shell thickness ‐ in production | Blue | 1A | Rear | Red | 1,972 ‐ 1,963 | | | | Blue | 1,982 ‐ 1,973 | | | Others | Red | 1,974 ‐ 1,965 | | | | Blue | 1,984 ‐ 1,975 | | Gold | 2A | Rear | Red/white | 2,097 ‐ 2,088 | | | | Orange/blue | 2,107 ‐ 2,098 | | | Others | Red/white | 2,099 ‐ 2,090 | | | | Orange/blue | 2,109 ‐ 2,100 | | Red | 2B | Rear | White | 2,297 ‐ 2,288 | | | | Orange | 2,307 ‐ 2,298 | | | Others | White | 2,290 ‐ 2,295 | | | | Orange | 2,309 ‐ 2,300 | Service main bearing shells (in sets) | A | 1 | 1A | Top red Bottom blue | | 2; re‐ground | 2A | One class No colour | | 3; re‐ground | 3A | One class No colour | | 4; re‐ground | 4A | One class No colour | | B | 1 | 1B | One class No colour | | 2; re‐ground | 2B | Top white Bottom orange | | 3; re‐ground | 3B | One class No colour | | 4; re‐ground | 4B | One class No colour | Big‐end bearing shells ‐ available for following crankshaft sizes | 1 | 60,00 | 1,729 | | 2 | 59,75 | 1,854 | | 3 | 59,50 | 1,988 | | 4 | 59,25 | 2,113 | Lubricants, Adhesives, Coolants and Sealers | Grease for input shaft splines and sliding face of clutch release bearing on guide sleeve | ESDM‐1C220‐A | | Grease for timing belt tensioner mounting face | SM1C‐4515‐A | | Thread‐locking compound ‐ Loctite 270 | SDM‐4G‐9107‐A | | Sealer ‐ non‐hardening ‐ Hylomar PL32M | SPM‐4G‐9112‐F | | Super‐Plus 4 Coolant Concentrate | ESD‐M97B‐49‐A | | Engine oil ‐ initial fill incl. filter | 7 | | Engine oil ‐ oil change without filter change | 5,75 | | Engine oil ‐ oil change incl. filter change | 6 | | Coolant | 11,6 | | Recommended engine oil: | | | | SAE 10W30 / ‐20 to over 40 degrees Centigrade | 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 / ‐20 to over 40 degrees Centigrade | Ford Formula S Synthetic Engine Oil | ACEA A3‐96/B3‐96 or API/SH/CD EC | | SAE 10W40 / ‐20 to over 40 degrees Centigrade | Ford XR+ High‐performance High‐lubricity Engine Oil | ACEA A3‐96/B3‐96 or API/SH/CD EC | | SAE 15W40 / ‐15 to over 40 degrees Centigrade | Ford Super Multigrade Engine Oil | ACEA A2‐96/B2‐96 or A3‐96/B3‐96 or API/SG/CD | | SAE 5W30 / ‐20 to over 10°C | Ford Formula E Economy Engine Oil | ACEA A1‐96/B1‐96 and WSS‐M2C912‐A1 | |  | NOTE: The engine oil to specification SAE 5W30 has only been approved for use in northern European territories. | If engine oils with these specifications are not available, use only engine oils which conform to specifications API SH/CD EC and CCMC PD2 or better. | Bracket of front exhaust pipe | 24 | 18 | | Lock panel to radiator | 11 | 8 | | Support brace to crossmember | 11 | 8 | | Radiator grille | 11 | 8 | | Exhaust manifold to cylinder head | 47 | 35 | | Front exhaust pipe to exhaust manifold | 50 | 37 | | Front exhaust pipe to rear exhaust pipe | 38 | 28 | | Drive belt tensioning bracket | 23 | 17 | | Alternator mounting bolt | 23 | 17 | | Clamp bolt of steering intermediate shaft | 30 | 22 | | Steering gear to crossmember | 50 | 37 | | EGR cooler bracket | 23 | 17 | | EGR cooler | 23 | 17 | | EGR pipe to exhaust manifold | 23 | 17 | | Engine mounting bracket to cylinder block | 55 | 41 | | Engine mounting bracket to transmission | 62 | 46 | | Engine mounting nuts | 50 | 37 | | Fuel pump heat shield | 23 | 17 | | Fuel filter | 17 | 12 | | Fuel injection pipes | 19 | 14 | | Driveshaft centre bearing to floor assembly | 33 | 24 | | Driveshaft to transmission | 84 | 62 | | Gear lever to transmission housing | 25 | 19 | | Transmission to engine | 35 | 26 | | Fuel line bracket to transmission flange | 35 | 26 | | Clutch housing front cover | 25 | 19 | | Clutch housing adaptor plate | 10 | 7 | | Transmission to rear transmission mounting | 84 | 62 | | Bolt/nut of rear transmission mounting to transmission crossmember | 84 | 62 | | Starter motor to transmission flange | 35 | 26 | | Starter motor earth lead to transmission flange | 35 | 26 | | Cylinder head to cylinder block ‐ Stage 1 | 70 | 52 | | Cylinder head to cylinder block ‐ Stage 2 | 70 | 52 | | Cylinder head to cylinder block ‐ Stage 3 | 90° | 90° | | Crankshaft rear oil seal housing to cylinder block | 19 | 14 | | Allen screws ‐ rear oil seal housing | 14 | 10 | | Flywheel to crankshaft ‐ Stage 1 | 21 | 15 | | Flywheel to crankshaft ‐ Stage 2 | 30° | 30° | | Timing belt cover to adaptor plate | 7 | 5 | | Clutch pressure plate to flywheel | 30 | 22 | | Cylinder head cover ‐ Stage 1 | 7 | 5 | | Cylinder head cover ‐ Stage 2 | 7 | 5 | | Rocker shaft bearing pedestal bolts, M8 | 29 | 21 | | Rocker shaft bearing pedestal bolts, M10 | 66 | 49 | | Rocker arm adjusting bolt, min. | 12 | 9 | | Rocker arm adjusting bolt, max. | 48 | 35 | | Bolt ‐ injector retaining plate | 40 | 30 | | Thermostat housing to cylinder head | 23 | 17 | | Temperature gauge sender unit | 15 | 11 | | Engine lifting eye | 23 | 17 | | Bracket for supporting engine lifting bracket | 23 | 17 | |
