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303-01A Engine - 2.0L Zetec-E (Zetec)|Description and Operation > < Bearing Inspection

Maverick 2001 (12.2000-07.2004)

Engine - 2.0L Zetec-E (Zetec) - Specifications Maverick 2001 (12/2000-07/2004)

General Specifications

Item Specification
Displacement (CID) 2.0L (121 cubic inches)
Number of cylinders 4
Bore and stroke
  • 84.8 x 88.0 mm
  • (3.34 x 3.46 inches)
Firing order 1-3-4-2
Oil pressure (hot 4,000 rpm)
  • 370-550 kpa
  • (54-80 psi)
Timing belt tension 178-311 N (40-70 lbs)
Compression ratio 9.6: 1
Coolant capacity 6.6L (1.75 gal)
Cylinder head and valve train
Valve to valve guide clearance
  • 0.017-0.064 mm
  • (0.000662-0.0025196 inch)
Valve clearance—intake valve
  • 0.11-0.18 mm
  • (0.004331-0.007087 inch)
Valve clearance—exhaust valve
  • 0.27-0.34 mm
  • (0.0106299-0.0133858 inch)
Angle degrees runout (total indicated runout) 90 degrees
Valve guide bore diameter (insert counterbore diameter)
intake 6.06 mm (0.23858 inch)
exhaust 6.06 mm (0.23858 inch)
Head gasket surface flatness 0.05/0.520/076 150 x 150
Head face surface finish 15 microns max
Valve head diameter
intake 32.0 mm (1.2598 inch)
exhaust 28.0 mm (1.10236 inch)
Valve face runout limit intake and exhaust 0.035 mm (0.0013779 inch)
Valve face angle 45 degrees
Valve stem diameter
intake 6.03 mm (0.23740 inch)
exhaust 6.03 mm (0.23740 inch)
  • Valve springs compression pressure
  • (N (lb) @ mm (in))
intake 365 N (82.1 lb) @ 25.1 mm (0.988 inch)
exhaust 422 N (94.94 lb) @ 26.1 mm (1.0275 inch)
Free length 43.2 mm (1.701 inch)
Installed height 34.2 mm (1.346 inch)
Valve springs assembled height service limit, pressure lost @ specific height 34.2 mm (1.346 inch) ± 0.65 mm (0.0256 inch)
intake 145 N (32.596 lb)
exhaust 180 N (40.464 lb)
Camshaft
Lobe lift
intake 8.9 mm (0.0137 inch)
exhaust 8.7 mm (0.0134 inch)
Theoretical valve maximum lift
intake 9.254 mm (0.3643 inch)
exhaust 8.6 mm (0.33858 inch)
End play service limit
  • 0.080-0.220 mm
  • (0.00315-0.00866 inch)
Bearing journal diameter
  • 25.960-25.980 mm
  • (1.0221-1.0227 inch)
Camshaft bearing radial clearance
  • 0.020-0.070 mm
  • (0.000787-0.002756 inch)
Cylinder block
Cylinder bore diameter
Class-1
  • 84.800-84.810 mm
  • (3.338576-3.3389697 inch)
Class-2
  • 84.810-84.820 mm
  • (3.3389697-3.3393634 inch)
Class-3
  • 84.820-84.830 mm
  • (3.3393634-3.3397571 inch)
Piston to cylinder bore clearance 0.05 mm (0.0019685 inch)
Surface finish (ra) each bore min 2.0-6.0 microns
Out of round limit 0.025 mm (0.0009842 inch) max
Taper limit +0.025 (0.0009842 inch) - 0.013 mm (0.0005118 inch) max
Main bearing bores inside diameter (bearing caps installed)
  • 58.011-58.0380 mm
  • (2.28389-2.284956 inch)
Main bearing bores inside diameter (bearing caps installed) bearing caps graded by size
  • 58.008-58.031 mm
  • (2.2837749-2.284680 inch)
Main bearing radial clearances
  • 0.011-0.058 mm
  • (0.000433-0.002833 inch)
Main bearing radial clearances bearing caps graded by size
  • 0.0196-0.044 mm
  • (0.0007716-0.0017322 inch)
Crankshaft
Main bearing journal diameter
  • 57.980-58.000 mm
  • (2.2826726-2.28346 inch)
Main bearing journal end play
  • 0.09-0.26 mm
  • (0.0035433-0.010236 inch)
Connecting rod bearing journal diameter
  • 46.89-46.91 mm
  • (1.846059-1.850036 inch)
Connecting rod
Connecting rod bearing clearance to crankshaft
  • 0.016-0.070 mm
  • (0.0006299-0.0027559 inch)
Connecting rod piston pin bore diameter
  • 20.589-20.609 mm
  • (0.810589-0.811376 inch)
Crankshaft bearing bore diameter
  • 46.89-46.91 mm
  • (1.846059-1.846847 inch)
Pistons
Piston to bore clearance
  • 0.010-0.030 mm
  • (0.0003937-0.0011811 inch)
Piston diameter
Class-1
  • 84.781-84.799 mm
  • (3.337828-3.338537 inch)
Class-2
  • 85.276-85.294 mm
  • (3.357316-3.3358025 inch)
Piston bore diameter
  • 19.99-20.01 mm
  • (0.7870063-0.7877937 inch)
Ring width
Upper compression ring
  • 0.30-0.50 mm
  • (0.011811-0.019685 inch)
Lower compression ring
  • 0.30-0.50 mm
  • (0.011811-0.019685 inch)
Oil control ring
  • 0.40-1.40 mm
  • (0.015748-0.055118 inch)
Ring groove width
Upper compression ring
  • 1.484 mm
  • (0.058425 inch)
Lower compression ring
  • 1.734 mm
  • (0.0682675 inch)
Oil control ring
  • 2.905 mm
  • (1.1143698 inch)
Piston pin length
  • 63.00-63.80 mm
  • (2.48031-2.51181 inch)
Piston pin diameter
White-
  • 20.662-20.625 mm
  • (0.8134629-0.8120062 inch)
Red-
  • 20.625-20.628 mm
  • (0.8120062-0.8121243 inch)
Blue-
  • 20.628-20.631 mm
  • (0.8121243-0.8122424 inch)
Squish height
Piston-to-piston pin interference fit
  • 0.010-0.015 mm
  • (0.0003937-0.0005905 inch)
Piston pin clearance in connecting rod bore
  • 0.016-0.049 mm
  • (0.0006299-0.0019291 inch)
Lubrication system
Oil pump type Gerotor
Oil capacity with filter 4.25 l (4.5 qts)
Lubricant
  • Super Premium SAE 5W-20 Motor Oil
 WSS-M2C153-H
  • Stud and Bearing Mount
  • E0AZ-19554-BA
 WSK-M2G349-A1
  • Gasket Maker
  • F8AZ-19B508-AB
 WSK-M2G348-A5
  • Silicone Gasket and Sealant
  • F7AZ-19554-EA
 WSE-M4G323-A4

Torque Specifications

Description Nm lb-ft lb-in
A/C compressor bracket bolts 24 18 —
A/C compressor bracket nuts 48 35 —
Accessory drive belt idler pulley 45 35 —
Battery cable nut (starter) 12 9 —
Block heater screw 3 — 27
Camshaft cap bolts 19 14 —
Camshaft sprocket bolts 68 50 —
Catalytic converter bracket bolts 24 18 —
Cylinder head bolts

a

 a —
Clutch pressure plate bolts 24b 18b —
Clutch slave cylinder bolts 22 16 —
Coil bracket bolts 20 15 —
Coolant tube bolt/nut 20 15 —
Coolant tube bracket bolt (oil cooler) 10 — 89
Coolant tube stud 24 18 —
Crankcase vent oil separator bolts 10 — 89
Crankshaft rear oil seal housing bolts a a —
Crankshaft position sensor bolt 8 — 71
Crankshaft pulley bolt 115 85 —
Cylinder head temperature sensor 10 — 89
Exhaust gas recirculation (EGR) tube nuts 62 46 —
EGR tube bracket bolt 10 — 89
EGR tube bracket bolt 25 18 —
EGR tube bracket nut (lifting eye) 25 18 —
Engine lifting eye nut (rear) 15 11 —
Engine lifting eye bolt (front) 35 26 —
Engine mount bolts/nut 55 41 —
Engine mount ground wire nut (engine) 9 — 80
Engine mount ground wire nut (body) 10 — 89
Engine mount lower bracket bolts 50 37 —
Engine mount bolts/nut 34 25 —
Engine/transaxle mounting bolts—automatic transaxle 47 35 —
Engine/transaxle mounting bolts—manual transaxle 45 33 —
Exhaust manifold bolts/nuts 16

b

 12b —
Flywheel/flexplate bolts 112 83 —
Front transaxle mount through bolt 90 66 —
Generator bolts 45 33 —
Generator bracket bolt (upper) 24 18 —
Generator bracket bolts/nut (lower) 47 35 —
Generator wire nut 8 — 71
Ground cable bolt (automatic transaxle) 23 17 —
Ground cable bolt (manual transaxle) 9 — 80
Ground wire bolt (fender) 9 — 80
Ground wire bolt (automatic transaxle bracket) 10 — 89
Ground wire bolt (manual transaxle bracket) 9 — 80
Inner timing belt cover bolts 10 — 89
Intake manifold bolts/nuts 18b 13b —
Knock sensor nut 20 15 —
LH transaxle mount bolt (engine) 90 66 —
LH transaxle mount bolts (body) 55 41 —
Lower cylinder block bolts 30b 22b —
Lower engine mount bracket bolts 50 37 —
Lower engine mount bracket studs 34 25 —
Lower timing belt cover bolts 7 — 62
Lower splash shield bolts 9 — 80
Oil cooler bolt 58 43 —
Oil filter 16 12 —
Oil level indicator and tube nut 10 — 89
Oil pan bolts a a a
Oil pan drain plug 25 18 —
Oil pressure sender 27 20 —
Oil pump bolts a a a
Oil pump screen cover and tube bolts 10 — 89
Output shaft speed sensor bolt 13 10 —
Powertrain control module (PCM) connector bolt 6 — 53
PCM ground wire bolt 9 — 80
Positive crankcase ventilation tube bolt 10 — 89
Power distribution box cable nuts 12 9 —
Power steering line bracket (pump) 20 15 —
Power steering line bracket bolt (head) 10 — 89
Power steering line bracket bolts (rack) 10 — 89
Power steering line bracket bolts (body) 10 — 89
Power steering pump bolts 25 18 —
Power steering pump bracket bolts 27 20 —
Rear transaxle mount bolts 55 41 —
Selector cable bracket bolts 23 17 —
Shifter shaft bolt/nut 20 15 —
Shifter strut rod bolt 45 33 —
Speed control unit nuts 10 — 89
Starter bolts 25 18 —
Starter control wire nut 5 — 44
Thermostat housing bolts 20 15 —
Throttle cable bracket bolt 10 — 89
Timing belt idler pulley bolt 25 18 —
Timing belt tensioner bolt 25 18 —
Torque converter nuts 36 27 —
Upper timing belt cover bolts 8 — 71
Valve cover bolts 9 — 80
Water pump adapter bolts 20 15 —
Water pump pulley bolts 25 18 —
Wire harness connector bolt 10 — 89

a Refer to procedure for tightening specifications.

b Refer to the procedure for tightening sequences.

303-01A Engine - 2.0L Zetec-E (Zetec)|Description and Operation > < Bearing Inspection