Engine Data | | 2.0L | | Engine management | EEC V/SFI | | Emission standard | 94/12/EC; Euro 2 | | Fuel | Super 95 RON unleaded | | Firing order | 1-3-4-2 | | Bore mm | 84,8 | | Stroke mm | 88,0 | | Cubic capacity (cm3) | 1.989 | | Compression ratio | 10,0:1 | | Engine power (kW/PS) | 91/125 | | at (rev/min) | 6000 | | Torque (Nm) | 180 | | at (rev/min) | 4000 | | Idle speed (rev/min) (manual transmission) | 800 | | Engine speed limit (rev/min) | 7100 | Engine oil, Zetec-E up to 07/98 | Designation | Viscosity/ambient temperature | Specification | | Recommended engine oil | | | | Ford Formula E Economy Engine Oil | SAE 5W-30 / below -20 degrees C to over +40 degrees C | WSS-M2C913-A or WSS-M2C912-A1 | | Alternative engine oils | | | | Ford Super Multigrade Engine Oil | SAE 10W-30 / -20 degrees C to over +40 degrees C | ACEA A1/B1, A2/B2 or A3/B3 | | Ford XR+ High-performance High-lubricity Motor Oil | SAE 10W-40 / -20 degrees C to over +40 degrees C | ACEA A3/B3 | | Ford Formula S Synthetic Motor Oil | SAE 5W-40 / below -20 degrees C to over +40 degrees C | ACEA A3/B3 | Engine oil, Zetec-E from 08/98 | Designation | Viscosity/ambient temperature | Specification | | Recommended engine oil | | | | Ford Formula E Economy Engine Oil | SAE 5W-30 / below -20 degrees C to over +40 degrees C | WSS-M2C913-A or WSS-M2C912-A1 | | Alternative engine oils | | | | Ford XR+ High-performance High-lubricity Motor Oil | SAE 10W-40 / -20 degrees C to over +40 degrees C | ACEA A3/B3 | | Ford Formula S Synthetic Motor Oil | SAE 5W-40 / below -20 degrees C to over +40 degrees C | ACEA A3/B3 | Lubricants, Fluids, Sealers and Adhesives | Item | Specification | | Transmission fluid (MTX 75) | ESD-M2C186-A | | Transmission fluid (CD4E) | ESPM-2C-166-H | | Sealer - camshaft bearing caps | WSK-M2G348-A2 | | Sealer - camshaft bearing caps (alternative) | WSK-M2G348-A5 | | Sealant, cylinder block (Hylosil 502) | WSK-M4G320-A | | Sealant, cylinder block (Loctite Ultrablack) (alternative) | WSE-M4G320-A2 | | Sealant, crankshaft position sensor | ESW-1C155-A | | Sealant, crankshaft position sensor (alternative) | WSD-M1C-226-A | | Sealant, oil pan | WSE-M4G323-A6 | | Thread locking compound | SDM-M4G9107-A | | Spark plug thread lubricant (Never Seeze) | WSD-M13P8-A | | Lubricant, injection nozzle O-rings | WSEM-2C903-A1 | | High performance brake fluid DOT 3 | C6AZ-19542-AA | | High performance brake fluid DOT 4 | SAM-6C9103-A | Capacities | | Litres | | Engine oil, initial fill incl. filter | 4,35 | | Engine oil, oil change incl. filter | 4,25 | | Engine oil, oil change excl. filter | 3,75 | | Coolant (with manual transmission/automatic transmission) | 6,6 | | Transmission fluid (MTX 75) | 2,6 | | Transmission (CD4E with fluid cooler) * = new transmissions are already filled with 3,5 litres | 7,2* | Dimensions | Cylinder block | | 2.0L | | Number of main bearings | | 5 | | Cylinder bore Ø, class 1. | mm | 84,800-84,810 | | Cylinder bore Ø, class 2. | mm | 84,810-84,820 | | Cylinder bore Ø, class 3. | mm | 84,820-84,830 | | Inner Ø, main bearing shells (installed) | mm | 58,011-58,038 | | Inner Ø, main bearing shells (installed) (main bearing shells with stepped sizes) | mm | 58,008-58,031 | | Main bearing radial clearance | mm | 0,011-0,058 | | Radial clearance, main bearing (main bearing shells with stepped sizes) | mm | 0,0196-0,044 | | Main bearing parent bore dia. | mm | 62,287-62,300 | Dimensions | Crankshaft | | 2.0L | | Main bearing journal Ø | mm | 57,980-58,000 | | Main bearing journal end float | mm | 0,09-0,26 | | Big-end bearing journal Ø | mm | 46,89-46,91 | Dimensions | Lower crankcase | | 2.0L | | Required spacer washer thickness if there is a gap between the cylinder block and the lower crankcase: | | | | 0,26 mm to 0,50 mm | mm | 0,25 | | 0,51 mm to 0,75 mm | mm | 0,50 | Dimensions | Connecting Rods | | 2.0L | | Bore diameter, big end | mm | 49,89-49,91 | | Bore diameter, small end | mm | 19,951-19,981 | | Inner Ø, big end bearing shells (installed) | 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 | | 2.0L | | Piston Ø, class 1. | mm | 84,750-84,760 | | Piston Ø, class 2. | mm | 84,760-84,770 | | Piston Ø, class 3. | mm | 84,770-84,780 | | Piston clearance in cylinder | mm | -0,010-0,030 | | Piston ring gap (installed), upper compression ring | | | | - upper compression ring Piston ring gap (installed), upper compression ring | mm | 0,22-0,37 | | - lower compression ring | mm | 0,50-0,70 | | - oil scraper ring | mm | 0,15-0,66 | | Ring gap position | | The piston ring gaps must be distributed evenly around the circumference of the piston. This also applies to the oil scraper ring elements. Align the ring gaps at 120 degrees to each other. | Dimensions | Piston Pins | | 2.0L | | Piston pin length | mm | 55,80-56,20 | | Piston pin Ø, white | mm | 19,997-20,000 | | Piston pin Ø, red | mm | 20,625-20,628 | | Piston pin clearance in piston | mm | 0,016-0,049 | Dimensions | Camshaft | | 2.0L | | Number of camshaft bearings | | 5 | | Drive | | Drive belt | | Bearing journal Ø | mm | 25,960-25,980 | | Camshaft bearing radial clearance | mm | 0,020-0,070 | | Camshaft end float | mm | 0,080-0,220 | Dimensions | Valves | | 2.0L | | Valve clearance in the valve guide | | | | - Inlet valve | mm | 0,017-0,064 | | - Exhaust valve | mm | 0,017-0,064 | | Inlet valve clearance (at 20° C ± 5° C) | mm | 0,11-0,18 | | Exhaust valve clearance (at 20° C ± 5° C) | mm | 0,27-0,34 | Dimensions | Cylinder Head | | 2.0L | | Maximum distortion (mating surface) | mm | 0,1 | | Height of mating surface | mm | 2,0 +0,12 -0,24 | | Peak-to-valley height of mating surface (reference length 2.5 mm vertical to groove direction) | μm | R 3z= 6,0 | | Oil pressure at 800 - 850/min | bar | 1,3-2,5 | | Oil pressure at 4000/min | bar | 3,7-5,5 | In the 2.0l engine, the piston cooling nozzles are fully open at 4000/min. This results in a pressure loss of 0.3 - 0.8 bar, meaning that the 2.0l engine can be in the lower pressure range. Torque Specifications | Description | Nm | lb-ft | lb-in | | Hose clamps | 4 | - | 35 | | Intake air | | | | | Inlet manifold studs | 5 | - | 44 | | Inlet manifold bolts and nuts | 18 | 13 | - | | Throttle body | 7 | - | 62 | | Exhaust gas recirculation valve | 9 | - | 80 | | Heat shield to cylinder head (M6) | 10 | - | 89 | | Heat shield to cylinder head and exhaust manifold (M8) | 16 | 12 | - | | Exhaust system | | | | | Exhaust manifold studs | 5 | - | 44 | | Exhaust manifold nuts | 15 | 11 | - | | Catalytic converter to exhaust manifold | 41 | 30 | - | | Catalytic converter to exhaust | 45 | 33 | - | | Idle speed control valve | 10 | - | 89 | | Driveshafts | | | | | Right-hand driveshaft centre bearing | 27 | 20 | - | | Driveshaft centre bearing to engine | 48 | 35 | - | | Generator | | | | | Generator to bracket | 25 | 18 | - | | Generator bracket to cylinder block | 65 | 48 | - | | Transmission | | | | | Transmission flange bolts | 48 | 35 | - | | Starter motor to transmission | 48 | 35 | - | | Oil drain plug, transmission | 35 | 26 | - | | Oil control plug, transmission | 35 | 26 | - | | Automatic transmission fluid cooler lines | 23 | 17 | - | | Flywheel/drive plate | 112 | 83 | - | | Clutch pressure plate | 29 | 21 | - | | Crossmember | | | | | Subframe to body | 130 | 96 | - | | Steering gear to subframe | 130 | 96 | - | | Radiator bracket on subframe | 10 | - | 89 | | Air Conditioning | | | | | Air conditioning compressor to bracket | 25 | 18 | - | | Dehydrator on subframe | 11 | 8 | - | | 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 to transmission (MTX 75) | 84 | 62 | - | | Left-hand engine roll restrictor to transmission (MTX 75) | 84 | 62 | - | | Central bolt, left- and right-hand engine roll restrictors | 120 | 89 | - | | Rear engine mounting to the transmission. | 83 | 61 | - | | Bracket, front engine mounting to engine and to engine mounting | 83 | 61 | - | | Wheel 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 | - | | Track rod to spindle carrier | 26 | 19 | - | | Stabiliser bar link rod to suspension strut | 47 | 35 | - | | Power steering | | | | | Power steering pump to bracket | 47 | 35 | - | | Bracket from air conditioning/power steering pump to cylinder block. | 47 | 35 | - | | Steering gear heat shield | 24 | 18 | - | | Steering gear to subframe | 130 | 96 | - | | Cylinder head | | | | | Camshaft position sensor to cylinder head | 20 | 15 | - | | Cylinder head bolts, stage 1 | 25 | 18 | - | | Cylinder head bolts, stage 2 | 45 | 33 | - | | Cylinder head bolts, stage 3 | 105 degrees | 105 degrees | 105 degrees | | Camshaft bearing caps | 19 | 14 | | | Cylinder head cover, 1st stage | 2 | - | 18 | | Cylinder head cover, magnesium, 2nd stage | 7 | - | 62 | | Cylinder head cover, plastic, 2nd stage | 9 | - | 80 | | Timing belt tensioner spring retaining pin | 10 | - | 89 | | Timing belt tensioner | 25 | 18 | - | | Inlet camshaft timing pulley | 68 | 50 | - | | Exhaust camshaft timing pulley | 68 | 50 | - | | Blanking plug, exhaust camshaft pulley | 37 | 27 | - | | Upper timing belt cover | 4 | - | 35 | | Blanking plug, oil gallery | 15 | 11 | - | | Ignition coil (EI) bracket to cylinder head | 21 | 15 | - | | Power steering pump bracket to cylinder head | 47 | 35 | - | | Thermostat housing | 20 | 15 | - | | Fuel rail | 10 | - | 89 | | Rear engine lifting eye | 16 | 12 | - | | Rear engine lifting eye studs | 6 | - | 53 | | Front engine lifting eye | 47 | 35 | - | | Cylinder block | | | | | Engine oil drain plug | 25 | 18 | - | | Oil pressure switch | 27 | 20 | - | | Cylinder block oil gallery blanking plugs | 23 | 17 | - | | Heater pipe bracket to oil pan | 10 | - | 89 | | Oil pan to lower crankcase, stage 1 | 24 | 18 | - | | Oil pan to lower crankcase, stage 2 | 11 | 8 | - | | Lower crankcase to cylinder block | 30 | 22 | - | | Oil pump | 11 | 8 | - | | Oil intake pipe to oil pump | 10 | - | 89 | | Main bearing cap bolts | 83 | 61 | - | | Big end bearing cap bolts (stage 1) | 25 | 18 | - | | Big end bearing cap bolts (stage 2) | 90 degrees | 90 degrees | 90 degrees | | Coolant pump | 18 | 13 | - | | Crankshaft rear oil seal carrier | 30 | 22 | - | | Drive belt idler pulley | 40 | 30 | - | | Crankcase ventilation pipe bracket | 22 | 16 | - | | Crankcase ventilation | 10 | - | 89 | | Coolant pump pulley | 24 | 18 | - | | Crankshaft belt pulley | 115 | 85 | - | | Crankshaft position sensor bracket | 21 | 15 | - | | Crankshaft position sensor to bracket | 8 | - | 71 | | Upper idler pulley (to 01/99) | 38 | 28 | - | | Upper idler pulley (from 01/99) | 23 | 17 | - | | Lower idler pulley | 38 | 28 | - | | Knock sensor | 20 | 15 | - | | |
