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303-03 Engine Cooling > < Assembly|Installation|Engine

Focus 1999 (08.1998-12.2004)

Engine - 2.0L Duratec-ST (Zetec) - Specifications Focus 1999 (08/1998-12/2004)

Engine Data

Description 2.0L DOHC 16V
Engine code ALDA
Engine management Black Oak
Firing order 1-3-4-2
Bore 84.8 mm
Stroke 88.0 mm
Number of main bearings 5
Cubic capacity (cm 3) 1,988
Compression ratio 10.2:1
Maximum engine power 173 PS
Maximum engine speed 7,000 rpm
Maximum engine torque at 5,500 rpm 196 Nm

Engine Oil

Viscosity / ambient temperature Type Specification
Recommended engine oil
SAE 5W-30 / below -20°C to over +40°C Ford Formula E WSS-M2C913-B
Alternative engine oils (for top-up only)
SAE 10W-40 / -20°C to over +40°C Ford Formula XR+ ACEA A3/B3
SAE 5W-40 / below -20°C to over +40°C Ford Formula S/SD WSS-M2C917-A

Capacities

Litres
Engine oil, initial fill including filter 4.35
Engine oil, oil change including filter 4.25
Engine oil, oil change excluding filter 3.75

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Sealant, camshaft bearing caps WSK-M2G348-A5
Sealant, cylinder block mating faces (Hylosil 502) WSK-M4G320-A
Sealant, cylinder block mating faces (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-A1
Lubricant, injection nozzle O-rings WSEM-2C903-A1
Silicone grease for spark plug connector seal A696-M1C171-AA
High-temperature grease for clutch disc engagement splines ESD-M1C220-A

Cylinder Block

Description mm
Cylinder bore diameter, class 1. 84.800 - 84.810
Cylinder bore diameter, class 2. 84.810 - 84.820
Cylinder bore diameter, class 3. 84.820 - 84.830
Inner diameter, main bearing shells installed 58.011 - 58.038
Inner diameter, main bearing shells installed (main bearing shells with stepped sizes) 58.008 - 58.031
Main bearing radial clearance 0.011 - 0.058
Main bearing radial clearance (main bearing shells with stepped sizes) 0.020 - 0.042
Main bearing parent bore 62.287 - 62.300

Pistons

Description mm
Piston diameter, class 1. 84.770 - 84.780
Piston diameter, class 2. 84.780 - 84.790
Piston diameter, class 3. 84.790 - 84.800
Piston clearance in cylinder bore 0.010 - 0.030
Piston ring gaps (installed)
- upper compression ring 0.300 - 0.500
- lower compression ring 0.300 - 0.500
- oil scraper ring 0.400 - 1.400

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.

Crankshaft

Description mm
Main bearing journal diameter 57.980- 58.000
Main bearing journal end float 0.090 - 0.260
Connecting rod bearing journal diameter 46.890 - 46.910

Cylinder Block and Lower Crankcase Spacers

Description mm
Required spacer thickness if there is a gap between the cylinder block and the lower crankcase of:
0.26 mm - 0.50 mm 0.25
0.51 mm - 0.75 mm 0.50

Connecting Rod

Connecting rod mm
Big end bore diameter 49.890 - 49.910
Small end bore diameter 19.951 - 19.981
Inner diameter, connecting rod bearing shells installed 46.926 - 46.960
Radial connecting rod bearing clearance 0.016 - 0.070
Axial connecting rod bearing clearance 0.090 - 0.320

Piston Pin

Description mm
Piston pin length 55.800 - 56.200
Piston pin diameter, white 19.997 - 20.000
Piston pin diameter, red 20.625 - 20.628
Piston pin clearance in piston 0.010 - 0.019
Piston pin clearance in connecting rod 0.016 - 0.049

Camshaft

Description mm
Bearing journal diameter 25.960 - 25.980
Camshaft bearing radial clearance 0.020 - 0.070
Camshaft end float 0.080 - 0.220

Valves

Valves mm
Intake valve clearance in the valve guide 0.017 - 0.064
Exhaust valve clearance in the valve guide 0.017 - 0.064
Intake valve clearance (at 20 °C ± 5 °C) 0.21 -0.29
Exhaust valve clearance (at 20 °C ± 5 °C) 0.32 - 0.40

Cylinder Head

Cylinder head
Maximum distortion (mating surface) 0.1 mm
Height of mating surface 1.76 mm - 2.12 mm
Peak-to-valley height of mating surface (reference length 2.5 mm vertical to groove direction) R 3z = 6.0 μm
Oil pressure at 800 rpm - 850 rpm 1.3 bar - 2.5 bar
Oil pressure at 4000 rpm 3.7 bar - 5.5 bar

Torque Specifications

Description Nm lb-ft lb-in
Hose clamps 4 – 35
Intake manifold studs 5 – 44
Intake manifold bolts and nuts 18 13 –
Heat shield to exhaust manifold 10 – 89
Exhaust manifold studs 5 – 44
Exhaust manifold nuts 16 12 –
Exhaust manifold bolts 18 13 -
Catalytic converter to exhaust manifold 48 35 –
Catalytic converter to exhaust 47 35 –
Generator to bracket 25 18 –
Generator bracket to upper cylinder block bolts 25 18 –
Generator bracket to lower cylinder block bolts 65 48 –
Transmission flange bolts 47 35 –
Starter motor to transmission 35 26 –
Flywheel bolts 112 83 –
Clutch pressure plate 29 21 –
Engine roll restrictor to transmission 48 35 –
Engine roll restrictor to subframe 48 35 –
Engine rear mount to body 48 35 –
Engine rear mount (nut on transmission mount bracket) 133 98 –
Engine front mount to engine 80 59 –
Engine front mount to body 48 35 –
Power steering pump bracket 48 35 –
Cylinder head a) – –
Camshaft bearing cap 15 11 -
Cylinder head cover a) – -
Spark plugs 15 11 –
Timing belt tensioner 25 18 –
Camshaft timing belt pulley 68 50 –
Camshaft VCT unit 120 89 -
Camshaft VCT unit plug 38 25 -
Upper timing belt cover 8 – 71
Ignition coil (EI) bracket to cylinder head 21 15 –
Thermostat housing 20 15 –
Fuel rail 10 – 89
Engine rear lifting eye 20 15 –
Engine rear lifting eye studs 7 – 62
Engine front lifting eye 35 26 –
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 a) – -
Lower crankcase to cylinder block 30 22 –
Oil pump 11 8 –
Oil intake pipe to oil pump 10 – 89
Main bearing cap bolts a) - –
Connecting rod bearing cap bolts a) - –
Coolant pump 20 15 –
Rear crankshaft oil seal carrier 20 15 –
Drive belt idler pulley 40 30 –
Crankcase ventilation pipe bracket 23 17 –
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
Timing belt idler pulley 38 25 –
Knock sensor 20 15 –

a) Refer to the procedure in this section.

303-03 Engine Cooling > < Assembly|Installation|Engine