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303-01B Engine - 2.5L|Description and Operation > < 303-01A Engine - Vehicles Built Up To: 05-1998 1.6L-1.8L-2.0L|Engine

Mondeo 1997 (08.1996-09.2000)

Engine - 2.5L - Specifications Mondeo 1997 (08/1996-09/2000)

Engine Data

2,5 2,5 ST 200
Engine management EEC V EEC V
Emission standard up to 99,75 MY D3/Stage II D4
Emission standard from 2000 MY (vehicles with manual transmission) E3/D3 D4
Emission standard from 2000 MY (vehicles with automatic transmission) E3/D3 -
Engine code from 97 MY SEA -
Engine code from 99.75 MY - SGA
Engine code from 2000 MY SEB -
Engine code from 2000.5 MY SEC -
Firing order 1-4-2-5-3-6 1-4-2-5-3-6
Bore (mm), up to 99.75 MY 82,4 -
Bore (mm), from 99.75 MY 81,66 81,66
Stroke (mm) 79,5 79,5
Capacity (cm 3) up to 99,75 MY 2543 -
Capacity (cm 3) from 99,75 MY 2499 2499
Compression ratio 9,7:1 10,25:1
Engine power output (ISO) (kW) 125 151
Engine power output at (rev/min) 6250 6700
Torque (ISO) (Nm) 220 229
Torque at (rev/min) 4250 5500
Idle speed (rev/min) 725±50 725±50
Engine speed limit (rev/min) 6925 6925

Cylinder head and valve train, 2.5l engine

Component Specification
Combustion chamber volume 44.5±1.5 cc
Valve seat width, inlet 1.1-1.4 mm
Width, outlet 1.4-1.7 mm
Angle 44.75 degrees
Max. out-of-round (T.I.R.) 0.04 mm
Valve stem clearance, inlet 0.020-0.069 mm
Valve stem clearance, outlet 0.045-0.094 mm
Valve head diameter, inlet 32 mm
Valve head diameter, outlet 26 mm
Diameter 31 and 24.5 mm
Out-of-round limit, valve seat 0.05 mm
Valve seat angle 45.5 degrees
Valve stem diameter (STD), inlet 5.975-5.995 mm
Valve stem diameter (STD), outlet 5.950-5.970 mm
Valve spring pretension (N/spec. length), inlet 680 N/30.19 mm
Valve spring pretension (N/spec. length), outlet 680 N/30.19 mm
Free length (approximate), inlet 46.8 mm
Free length (approximate), outlet 46.8 mm
Spring tension when installed (N/spec. length), inlet 228 N/39.99 mm
Spring tension when installed (N/spec. length), outlet 228 N/39.99 mm
Wear limit 10 % pressure loss/30.09
Limit value for deviation from box form 1 %
Cam follower ratio 1,8:1
Hydraulic valve tappet diameter (STD) 16-15.988 mm
Bore play 0.018-0.069 mm
Wear limit 0.016 mm
Pressure loss 5-25 seconds
Desired clearance with valve tappet pressed in 0.50-1.11 mm

Camshaft, 2.5l engine

Component Specification
Cam lift
Inlet (primary) 4.79 mm
Inlet (secondary) 4.79 mm
Outlet 4.79 mm
Permitted cam lift loss 0 mm
Theoretical valve lift without play
Inlet (primary) 9.80 mm
Inlet (secondary) 9.80 mm
Outlet 9.80 mm
Axial play
Standard 0.025-0.165 mm
Wear limit 0.190 mm
Play between bearing journal and bearing
Standard 0.025-0.076 mm
Wear limit 0.121 mm
Bearing journal diameter (all) 26.926-26.936 mm
Bearing inside diameter (all) 27.012-26.897 mm

Cylinder block, 2.5l engine

Component Specification
Surface, cylinder block mating face
Warpage, cylinder block mating face 0.025/25x25/150x150
Warpage, cylinder block face 0.025/25x25.050/x150
Warpage, cylinder block mating face 0.025/25x25/150x150
Warpage, cylinder block mating face 0.025/25x25/150x150
Main bearing bore diameter 68.998-69.022 mm
Cylinder bore
Diameter, oversize 1 82.4-82.410 mm
Diameter, oversize 2 82.411-82.421 mm
Diameter, oversize 3 82.420-82.430 mm
Surface (RMS) 0.2-0.6 micrometers
Out-of-round limit value 0.015 mm
Out-of-round limit value 0.020 mm
Taper wear limit 0.006 mm

Crankshaft, 2.5l engine

Component Specification
Main bearing journal diameter 62.968-62.992 mm
Big-end bearing journal diameter 49.970-49.990 mm
Crankshaft end play 0.110-0.232 mm
Crankshaft lateral run-out on rear side of cylinder block 0.050 mm max.
Big-end bearing
Clearance to crankshaft 0.028-0.066 mm
Add bearing wall thickness (STD) 0.250 mm undersize - 0.125 mm to standard thickness or thickness class 2 1,503
Main bearing
Desired clearance to crankshaft 0.025-0.045 mm
Permitted clearance to crankshaft 0.025-0.050 mm
Bearing wall thickness, class 1 2.501 mm
Bearing wall thickness, class 2 2.505 mm
Bearing wall thickness, class 3 2.510 mm

Connecting rod, 2.5l engine

Component Specification
Piston pin bore diameter 21.071-21.032 mm
Length (centre-centre) 138.06-138.4 mm
Axial warpage (max. bore-bore difference) Pivot shaft hole and crankshaft bearing bore must be parallel and on the same vertical plane within the specified total difference if 101.5 mm is measured on each side of the centre line at the ends of a 203 mm long bar.
Flexing 0.050 mm to 25 mm
Bending 0.038 mm to 25 mm
Side play (mounted on crankshaft)
Standard 0.100-0.30 mm
Wear limit max. 0.35 mm

Piston, 2.5l engine

Component Specification
Diameter Measured 43 mm from the outside edge on the upper piston to the axis.
Code class 1 82.390-82.410 mm
Code class 2 82.398-82.442 mm
Code class 3 82.410-82.430 mm
Play between piston and eye 0.012-0.022 mm
Pin eye diameter 21.008-21.012 mm
Ring groove width
Compression ring groove (top)
Compression ring groove (bottom)
Oil scraper ring groove 3.030-3.055 mm
Piston pin
Length 55.05-55.47 mm
Diameter 21.011-21.013 mm
Piston pin play -0.005 to +0.001 mm
Play between pin and small end
Standard 0.004-0.020 mm
Wear limit 0.035 mm
Side play
Compression ring (top) 0.04-0.075 mm
Compression ring (bottom) 0.040-0.085 mm
Oil scraper ring Snug fit
Operating limit value 0.10 mm
Piston ring gap Specification 82.4 mm measured diameter
Measured diameter, compression ring (top) 0.100-0.250 mm
Measured diameter, compression ring (bottom) 0.27-0.42 mm
Measured diameter, oil scraper ring (steel rail) 0.15-0.65 mm
Operating limit value, compression ring (top) max. 0.50 mm
Operating limit value, compression ring (bottom) max. 0.65 mm
Operating limit value, oil scraper ring (steel rail) max. 0.90

Lubrication, 2.5l engine

Specification
Oil pressure (warm, 1500 rpm) 138-310 kPa (20-45 psi)

Drive belt tension, 2.5l engine

Specification
The specified belt tensions differ depending on whether the belts are newly installed or used. Automatic belt tensioner
6-fin water pump belt, front end accessory drive (FEAD) Automatic belt tensioner
3-fin water pump belt, rear end accessory drive (FEAD) No adjustment necessary

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Coolant ESD-M97B49-A
Transmission fluid (CD4E) ESP-M2C166-H
Transmission fluid (MTX 75) ESDM-2C186-A
Power steering hydraulic fluid ESP-M2C166-H
Sealer - lower crankcase to cylinder block, mating faces - oil pan to lower crankcase, mating faces - cylinder head covers to cylinder heads, keyway - crankshaft vibration damper. WSK-M4G320-A
Sealer - coolant plug to cylinder block ESK-M4G260-A
Sealer - oil pressure switch, blanking plugs - oil and coolant passages. SM-4G-4644-AA/AB
Sealer - flywheel bolts SDM-M4G9107-A
Lubricant - camshaft bearings SQM-2C9002-AA
Lubricant - piston running surfaces, bearing running surfaces, cam followers SQM-2C9002-AA
Lubricant - O rings - coolant connecting pipe ESD-M97B49-A
Lubricant - spark plugs (Never Seeze) ESE-M1244-A

Engine Oil
Type Viscosity/ambient temperature Specification
Recommended engine oil
Ford Formula E Economy Engine Oil SAE 5W-30 / under -20 °C to over +40 °C WSS-M2C913-A or WSS-M2C912-A1
Alternative engine oils
Ford Super Multigrade Engine Oil SAE 10W-30 / -20 °C to over +40 °C ACEA A1/B1, A2/B2 or A3/B3
Ford XR+ High Performance High Lubricity Engine Oil SAE 10W-40 / -20 °C to over +40 °C ACEA A3, B3
Ford Formula S Synthetic Engine Oil SAE 5W-40 / under -20 °C to over + 40 °C ACEA A3, B3

Capacities

Litres
Engine oil, initial fill incl. filter 5,85
Engine oil, incl. filter change 5,5
Engine oil, excl. filter change 5,0
Coolant (MTX 75) 9,5
Coolant (CD4E) 9,7
Transmission fluid (CD4E with oil cooler), total capacity 10,0*
Transmission fluid level (CD4E with oil cooler) Mark on the dipstick
Transmission fluid (MTX 75), total capacity 2,6
* = New transmissions are already pre-filled with 3.5 litres

Torque Specifications

Description Nm lb-ft lb-in
Air conditioning compressor 25 18
Lower suspension arm ball joint to spindle carrier 83 61
Tie-rod end 26 19
Stabiliser link rod to suspension strut 47 35
Brake calliper 120 88
Heat shield - right-hand front driveshaft center bearing 27 20
Oil pipe - oil cooler to automatic transmission 23 17
Steering gear to subframe 130 96
Subframe to body 130 96
Center bolt in subframe gauge 30 22
Front engine mounting 83 61
Rear engine mounting (CD4E) 48 35
Rear engine mounting (MTX-75) 83 61
Rear engine roll restrictor to subframe 48 35
Center bolt to rear engine roll restrictor 120 88
Front engine roll restrictor to subframe 48 35
Center bearing - right-hand front driveshaft to transmission 27 20
Center bolt to front engine roll restrictor 120 88
Torque converter to engine drive plate 36 27
Selector mechanism to body 44 32
Stabiliser bracket 55 41
Air conditioning dehydrator to subframe 11 8
Shift rod bracket 23 17
Shift linkage clamp bolt 16 12
Front exhaust pipe 40 30
Rear catalytic converter 40 30
Left and right-hand top suspension struts 46 34
Flange bolts 40 30
Starter motor bracket 48 35
Ground cable to automatic transmission housing 40 30
Wheel nuts 85 63
Driveshaft stub nuts 340 251
Mounting plate to cylinder block 47 35
Blanking plugs of oil and coolant passages, 1/4" 14 10
Blanking plugs of oil and coolant passages, 3/8" 20 15
Blanking plugs of oil and coolant passages, 1/2" 40 30
Blanking plugs of oil and coolant passages, 3/4" 68 50
Blanking plugs of oil and coolant passages, 1" 90 66
Blanking plug - oil pump 10 89
Oil pump cover to oil pump 10 89
Oil pump to cylinder block 10 89
Oil baffle to lower crankcase 10 89
Oil intake pipe to lower crankcase, M6 10 89
Oil intake pipe to lower crankcase, M8 25 18
Oil line to radiator 23 17
Oil separator to cylinder block 10 89
Engine mounting bracket to cylinder block 47 35
Cylinder head bolts, stage 1. 40 30
Cylinder head bolts, stage 2. 90° 90°
Cylinder head bolts, stage 3. -360° (undo) -360° (undo)
Cylinder head bolts, stage 4. 40 30
Cylinder head bolts, stage 5. 90° 90°
Cylinder head bolts, stage 6. 90° 90°
Lower crankcase to cylinder block - pre-tighten all bolts 4 35
Lower crankcase to cylinder block, Stage 1: Bolts 1 to 8 25 18
Lower crankcase to cylinder block - Stage 2: Bolts 9 to 16 40 30
Lower crankcase to cylinder block - Stage 3: Bolts 1 to 16 90° 90°
Lower crankcase to cylinder block - Stage 4: Bolts 17 to 22: 25 18
Connecting rod bearing caps, stage 1 23 17
Connecting rod bearing caps, stage 2 43 32
Connecting rod bearing caps, stage 3 90° 90°
Camshaft bearing caps to cylinder head 10 89
Camshaft oil seal housing to cylinder head 10 89
Fixed timing chain guide to cylinder block 25 18
Timing chain tensioner to cylinder block 25 18
Timing case cover to cylinder block 25 18
Wiring harness bracket to timing case cover 10 89
Camshaft position sensor to timing case cover 10 89
Crankshaft position sensor to timing case cover 10 89
Pulley/vibration damper to crankshaft, stage 1 120 88
Pulley/vibration damper to crankshaft, stage 2 -360° (undo) -360° (undo)
Pulley/vibration damper to crankshaft, stage 3 50 37
Pulley/vibration damper to crankshaft, stage 4 90° 90°
Power steering pump to carrier of engine mounting bracket 25 18
Power steering pump bracket to timing case cover 10 89
Pulley to power steering pump 25 18
Stud of the power steering pump 10 89
Spark plugs 14 10
Cylinder head cover to cylinder head 10 89
Wiring harness retaining plate to cylinder head cover 10 89
Engine lifting eye 112 83
Oil baffle to oil pan 10 89
Oil drain plug to oil pan 26 19
Oil pan to lower crankcase 25 18
Heat shields to oil pan 10 89
Oil cooler to cylinder block 57 42
Oil pressure switch to cylinder block 14 10
Exhaust manifold to cylinder head 20 15
Knock sensor to cylinder head 34 25
Generator bracket to cylinder block/lower crankcase 25 18
Generator mounting bolts 47 35
Bracket to generator 25 18
Engine drive plate to crankshaft 80 59
Flywheel to crankshaft 80 59
Camshaft oil seal carrier 10 89
Water pump to cylinder head, stage 1 10 89
Water pump to cylinder head, stage 2 90° 90°
Coolant connecting pipe to cylinder head 10 89
Positive crankcase ventilation bracket to coolant connecting pipe 6 53
Coolant distribution pipe to cylinder head 6 53
Oil dipstick tube bracket to coolant distribution pipe 10 89
Wiring harness to cylinder head cover 5 44
Generator power connection 10 89
Lower intake manifold to cylinder heads 10 89
Intake manifold runner control actuator 10 89
Upper intake manifold to cylinder head cover 10 89
EI coil to cylinder head cover 6 53
Ground cable to EI coil 6 53
Front driveshaft intermediate shaft bracket to cylinder block 47 35
Exhaust gas recirculation pipe to EGR valve 40 30
Unspecified screw connections: M5 x 0,8 6 53
Unspecified screw connections: M6 x 1 10 89
Unspecified screw connections: M8 x 1,25 25 18
Unspecified screw connections: M10 x 1,5 47 35
Unspecified screw connections: M12 x 1,75 82 60
Unspecified screw connections: M14 x 2 132 97

303-01B Engine - 2.5L|Description and Operation > < 303-01A Engine - Vehicles Built Up To: 05-1998 1.6L-1.8L-2.0L|Engine