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 | Emission standard | 96 EEC | 96 EEC | 96 EEC | Fuel | Premium 95 RON unleaded | Premium 95 RON unleaded | Premium 95 RON unleaded | Identification code | L1J | RKB | NGA | 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 | 100 | 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 / below -20°C to over +40°C | WSS-M2C913-A or WSS-M2C912-A1 | Alternative engine oils | | | Ford Super Multigrade Motor Oil | SAE 10W-30 / -20°C to over +40°C | ACEA A1/B1, A2/B2 or A3/B3 | Ford XR+ High-performance High-lubricity Motor Oil | SAE 10W-40 / -20°C to over +40°C | ACEA A3, B3 | Ford Formula S Synthetic Motor Oil | SAE 5W-40 / below -20°C to over +40°C | ACEA A3, B3 | 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) | 2,6 | Transmission fluid (CD4E with oil cooler) * = new transmissions are already filled with 3,5 liters of fluid. | 9,0* | Lubricants, Fluids, Sealers and Adhesives Item | Specification | Transmission fluid (MTX 75) | ESDM-2C186-A | Transmission fluid (CD4E) | ESP-M2C166-H | Sealer for camshaft bearing caps | 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 | 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 | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | Bore dia., big end | mm | 49,89 - 49,91 | 49,89 - 49,91 | 49,89 - 49,91 | Bore dia., small end | mm | 20,589 - 20,609 | 20,589 - 20,609 | 20,589 - 20,609 | Inside dia. - big-end bearing shells (fitted) | mm | 46,926 - 46,960 | 46,926 - 46,960 | 46,926 - 46,960 | Big-end bearing clearances (radial) | mm | 0,016 - 0,046 | 0,016 - 0,046 | 0,016 - 0,046 | Dimensions - piston | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | Piston dia., class 1. | mm | 75,975 - 75,985 | 80,570 - 80,580 | 84,770 - 84,780 | Piston dia., class 2. | mm | 75,985 - 75,995 | 80,580 - 80,590 | 84,780 - 84,790 | Piston dia., class 3. | mm | 75,995 - 76,005 | 80,590 - 80,600 | 84,790 - 84,800 | Piston clearance in cylinder | mm | 0,040 - 0,060 | 0,040 - 0,060 | 0,010 - 0,030 | Piston ring gaps (fitted) | | | | | Upper compression ring | mm | 0,30 - 0,50 | 0,30 - 0,50 | 0,30 - 0,50 | Lower compression ring | mm | 0,30 - 0,50 | 0,30 - 0,50 | 0,30 - 0,50 | Oil scraper ring | mm | 0,25 - 1,00 | 0,38 - 1,14 | 0,40 - 1,40 | Dimensions - piston pin | | 1,6 DOHC 16V | 1,8 DOHC 16V | 2,0 DOHC 16V | Piston pin length | mm | 63,00 - 63,80 | 63,00 - 63,80 | 63,00 - 63,80 | Piston pin dia., white | mm | 20,622 - 20,625 | 20,622 - 20,625 | 20,622 - 20,625 | Piston pin dia., red | mm | 20,625 - 20,628 | 20,625 - 20,628 | 20,625 - 20,628 | Piston pin dia., blue | mm | 20,628 - 20,631 | 20,628 - 20,631 | 20,628 - 20,631 | Piston pin clearance in piston | mm | 0,010 - 0,0151 | 0,010 - 0,0151 | 0,010 - 0,0151 | Interference fit in connecting rod | mm | 0,013 - 0,042 | 0,013 - 0,042 | 0,013 - 0,042 | 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 | 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) | mm | 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 | 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 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 - 1,8 engine) | 10 | | 89 | Heat shield and coolant pipe bracket to exhaust manifold (1,6 - 1,8 engine) | 23 | 17 | | Exhaust manifold studs | 6 | | 53 | Exhaust manifold nuts | 15 | 11 | | Catalytic converter to exhaust manifold | 40 | 30 | | Driveshafts | | | | Right-hand driveshaft center bearing | 27 | 20 | | Driveshaft bracket to engine | 48 | 35 | | Generator | | | | Generator to bracket | 50 | 37 | | Generator bracket to cylinder block | 47 | 35 | | Transmission | | | | Transmission 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 | | Track rod to spindle carrier | 26 | 19 | | Stabilizer link rod to suspension strut | 47 | 35 | | Power steering | | | | Power steering pump to bracket | 47 | 35 | | Bracket - air conditioning compressor/power steering pump to cylinder block. | 47 | 35 | | Cylinder head | | | | Camshaft position sensor to cylinder head | 21 | 15 | | Cylinder head bolts, stage 1. | 25 | 18 | | Cylinder head bolts, stage 2. | 45 | 33 | | Cylinder head bolts, stage 3. | 105° | 105° | | Camshaft bearing caps, stage 1. | 10 | | 89 | Camshaft bearing caps, stage 2. | 19 | 14 | | Cylinder head cover, stage 1. | 2 | | 18 | Cylinder head cover, stage 2. | 7 | | 62 | Spark plugs | 15 | 11 | | Retaining pin for timing belt tensioner spring | 10 | | 89 | Timing belt tensioner | 38 | 28 | | Camshaft timing pulley | 68 | 50 | | Upper timing belt cover | 4 | | 35 | 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 | | Power steering pump mounting plate 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 of 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 | | Oil splash nozzles and 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 | 80 | 59 | | Big-end bearing cap bolts, stage 1. | 16 | 12 | | 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 tube | 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 | | |