| Specifications | Engine management | | EEC V/SFI | | Emission standard | | 96 EEC | | Engine code | | NSD | | Firing order | | 1 ‐ 3 ‐ 4 ‐ 2 | | Bore | mm | 86,0 | | Stroke | mm | 86,0 | | Cubic capacity | cc | 1998 | | Compression ratio | | 9,8 : 1 | | Power output (EEC) | kW | 85 | | Power output (EEC) | PS | 115 | | Power output (EEC), at | rev/min | 5500 | | Torque (EEC) | Nm | 167 | | Torque (EEC), at | rev/min | 2500 | | Idle speed | rev/min | 875 | | Maximum permissible engine speed, continuous | rev/min | 5950 | | Maximum permissible engine speed, intermittent | rev/min | 6175 | | Cylinder block | | | | Cast mark | | 20 | | Cylinder bore ∅, standard class 1 | mm | 86,000 ‐ 86,010 | | Cylinder bore ∅, standard class 2 | mm | 86,010 ‐ 86,020 | | Cylinder bore ∅, oversize 0,15 | mm | 86,160 ‐ 86,170 | | Cylinder bore ∅, oversize 0,5 | mm | 86,500 ‐ 86,510 | | Number of main bearings | | 5 | | Centre main bearing width (excl. thrust half rings) | mm | 21,17 ‐ 21,23 | | Fitted main bearing shells | | | | Vertical inside ∅, service standard (yellow) | mm | 54,983 ‐ 55,020 | | Vertical inside ∅, standard | mm | 55,003 ‐ 55,030 | | Vertical inside ∅, 1st undersize 0,05 | mm | 54,953 ‐ 54,980 | | Vertical inside ∅, 2nd undersize 0,25 | mm | 54,753 ‐ 54,780 | | Vertical inside ∅, 3rd undersize 0,50 | mm | 55,503 ‐ 54,530 | | Main bearing parent bore ∅, standard | mm | 59,287 ‐ 59,300 | | Main bearing parent bore ∅, oversize 0,40 (black) | mm | 59,687 ‐ 59,700 | | Crankshaft | | | | End float | mm | 0,093 ‐ 0,303 | | Main bearing journal ∅, standard (yellow) | mm | 54,98 ‐ 54,99 | | Main bearing journal ∅, (red) | mm | 54,99 ‐ 55,00 | | Main bearing journal ∅, undersize 0,25 (green) | mm | 54,73 ‐ 54,75 | | Main bearing journal to shell clearance | mm | 0,011 ‐ 0,048 | | Big‐end bearing journal j, standard | mm | 50,89 ‐ 50,91 | | Big‐end bearing journal j, undersize 0,25 (green) | mm | 50,64 ‐ 50,66 | | Thrust half washer thickness, standard | mm | 2,301 ‐ 2,351 | | Thrust half washer thickness, oversize 0,38 (yellow) | mm | 2,491 ‐ 2,541 | | Width of centre main bearing journal, standard | mm | 26,025 ‐ 26,075 | | Width of centre main bearing journal, oversize 0,38 (yellow) | mm | 26,405 ‐ 26,455 | | Connecting rod | | | | Bore ∅, big‐end | mm | 53,890 ‐ 53,910 | | Bore ∅, small end | mm | 20,589 ‐ 20,609 | | Fitted big‐end bearing shells | | | | Vertical inside ∅, standard mm | mm | 50,916 ‐ 50,950 | | Vertical inside ∅, 1st undersize (0,25 mm) | mm | 50,666 ‐ 50,700 | | Vertical inside ∅, 2nd undersize (0,50 mm) | mm | 50,416 ‐ 50,150 | | Big‐end bearing journal to shell clearance | mm | 0,006 ‐ 0,060 | | Big‐end bearing end float | mm | 0,09 ‐ 0,31 | | Camshafts | | | | Number of camshaft bearings | | 2 x 5 | | Drive | | Single roller chain, hydraulic chain tensioner | | Camshaft end float | mm | 0,02 ‐ 0,26 | | Cam lift, inlet | mm | 10,83 | | Cam lift, exhaust | mm | 10,83 | | Cam length (between heel and toe), inlet | mm | 52,71 ‐ 52,94 | | Cam length (between heel and toe), exhaust | mm | 52,71 ‐ 52,94 | | Inlet valve opens before TDC | ° | 9 | | Inlet valve closes after BDC | ° | 51 | | Exhaust valve opens before BDC | ° | 51 | | Exhaust valve closes after TDC | ° | 9 | | Camshaft bearing journal ∅ | mm | 25,96 ‐ 25,98 | | Bearing inside diameter | mm | 26,00 ‐ 26,03 | | Pistons | | | | Uncoated piston ‐ ∅ (unused), service standard | mm | 85,970 ‐ 85,990 | | Uncoated piston ‐ ∅ (unused), oversize 0.15 | mm | 86,120 ‐ 86,140 | | Uncoated piston ‐ ∅ (unused), oversize 0.50 | mm | 86,460 ‐ 86,480 | | Piston clearance in bore (unused, piston uncoated), prod. | mm | 0,03 ‐ 0,05 | | Piston clearance in bore (unused, piston uncoated), service | mm | 0,02 ‐ 0,05 | | Coated piston ‐ ∅ (unused), service standard | mm | 85,990 ‐ 86,030 | | Coated piston ‐ ∅ (unused), oversize 0.15 | mm | 86,140 ‐ 86,180 | | Coated piston ‐ ∅ (unused), oversize 0.50 | mm | 86,480 ‐ 86,520 | | Piston clearance in bore (unused, piston coated), prod. | mm | 0,01 ‐ 0,03 | | Piston clearance in bore (unused, piston coated), service | mm | 0,02 ‐ 0,03 | | Piston pin length | mm | 63,4 | | Piston pin ∅, white | mm | 20,622 ‐ 20,625 | | Piston pin ∅, red | mm | 20,625 ‐ 20,628 | | Piston pin ∅, blue | mm | 20,628 ‐ 20,631 | | Clearance in piston (colour match) | mm | 0,008 ‐ 0,014 | | Interference fit in small end bore | mm | 0,016 ‐ 0,042 | | Piston ring gaps (fitted), top | mm | 0,30 ‐ 0,60 | | Piston ring gaps (fitted), middle | mm | 0,50 ‐ 0,80 | | Piston ring gaps (fitted), oil control ring (three part) | mm | 0,40 ‐ 1,50 | | Ring gap positions | | Piston ring gaps should be distributed evenly around the piston circumference; this also applies to the gaps of the intermediate oil control rings in relation to the expander gap. | | Valves | | | | Valve timing | | DOHC | | Valve clearances | | Hydraulic tappets | | Hydraulic tappet ∅ | mm | 42 | | Hydraulic tappet clearance in housing | mm | 0,025 ‐ 0,080 | | Valve length, inlet | mm | 108,24 ‐ 108,70 | | Valve length, exhaust | mm | 108,68 ‐ 109,20 | | Valve head ∅, inlet | mm | 42,5 ‐ 42,7 | | Valve head ∅, exhaust | mm | 37,9 ‐ 38,1 | | Valve stem ∅, standard (inlet) | mm | 7,025 ‐ 7,043 | | Valve stem ∅, standard (exhaust) | mm | 6,999 ‐ 7,017 | | Valve stem∅, oversize 0,2 (inlet) | mm | 7,255 ‐ 7,243 | | Valve stem∅, oversize 0,2 (exhaust) | mm | 7,199 ‐ 7,217 | | Valve stem∅, oversize 0,4 (inlet) | mm | 7,425 ‐ 7,443 | | Valve stem∅, oversize 0,4 (exhaust) | mm | 7,399 ‐ 7,417 | | Valve stem∅, oversize 0,6 (inlet) | mm | 7,625 ‐ 7,643 | | Valve stem∅, oversize 0,6 (exhaust) | mm | 7,599 ‐ 7,617 | | Valve stem∅, oversize 0,8 (inlet) | mm | 7,825 ‐ 7,843 | | Valve stem∅, oversize 0,8 (exhaust) | mm | 7,799 ‐ 7,817 | | Valve stem clearance in guide, inlet | mm | 0,020 ‐ 0,069 | | Valve stem clearance in guide, exhaust | mm | 0,046 ‐ 0,095 | | Colour code, outer spring | | Green/Blue | | Colour code, inner spring | | Green/Blue | | Free valve spring height, outer spring | mm | 48,2 | | Free valve spring height, inner spring | mm | 49,2 | | Valve spring inner ∅, outer spring | mm | 24 | | Valve spring inner ∅, inner spring | mm | 17,5 | | Valve spring wire (oval profile), outer spring | mm | 4,1 x 4,95 | | Valve spring wire ∅, inner spring | mm | 2,6 | | Number of turns, outer spring | | 6,83 | | Number of turns, inner spring | | 8,82 | | Lubrication | | | | Oil pressure at 875 rev/min (with SAE 10W/30 oil at a temperature of 80°) | bar | 1,60 | | Oil pressure at 2000 rev/min (with SAE 10W/30 oil at a temperature of 80°) | bar | 3,10 | | Pressure relief valve opens at | bar | 3,70 ‐ 4,60 | | Oil pressure warning light comes on at | bar | 0,30 ‐ 0,50 | | Oil pump rotor/housing clearance | mm | 0,154 ‐ 0,304 | | Inner/outer rotor clearance | mm | 0,05 ‐ 0,20 | | Rotor end float at mating face | mm | 0,014 ‐ 0,079 | | Cylinder head with valve seat inserts | | | | Cast mark | | 20 | | Upper correction angle (production), inlet/exhaust | ° | 25 | | Lower correction angle (production), inlet/exhaust | ° | 60 | | Valve seat angle | ° | 44,5 ‐ 45 | | Valve seat width, inlet | mm | 1,33 ‐ 2,19 | | Valve seat width, exhaust | mm | 1,68 ‐ 2,54 | | Stem bore (inlet/exhaust valve), standard | mm | 7,063 ‐ 7,094 | | Camshaft bearing parent bore ∅ (all) | mm | 26,00 ‐ 26,03 | | 0 to 0,25 mm | No adjustment | | | 0,26 to 0,29 mm | 0,15 mm | Silver | | 0,30 to 0,44 mm | 0,30 mm | Pale blue | | 0,45 to 0,59 mm | 0,45 mm | Red | | 0,60 to 0,75 mm | 0,60 mm | Black | Lubricants, Adhesives and Sealers | Transmission fluid | ESD‐M2C186‐A | | Coolant | ESD‐M97B49‐A | | Sealer for front oil seal carrier (Loctite 518) | WSK‐M2G348‐A5 | | Sealer for sump (Hylosil 502) | WSK‐M4G320‐A | | Sealer for coolant pump angle connector, coolant temperature sender unit, oil pressure switch (Loctite 243) | WSK‐M2G349‐A7 | | Lubricant for O‐ring of crankshaft position sensor (CKP) | SM1C‐115‐A | | Lubricant for clutch release bearing guide sleeve | ESD‐M1C‐220‐A | | Lubricant for transmission input shaft splines | ESD‐M1C‐220‐A | | Power steering fluid | SQM 2C‐9010‐A | | Thread‐locking compound (Loctite 270) | SDM‐M4G9107‐A | | Spark plug thread ('Never Seeze') | ESE‐M1244‐A | | Thread‐locking compound, power steering pump to bracket (Loctite 270) | SDM‐M4G9107‐A | | Silicone grease | A960‐M1C171‐AA | | Engine oil, initial fill including filter | 5,1 | | Engine oil, oil change with filter change | 4,25 | | Engine oil, oil change without filter change | 4,00 | | Coolant | 7,9 | | ‐10 to over 40° C | Ford Multigrade Super Engine Oil | SAE 20W50 API/SG/CD | | ‐15 to over 40° C | Ford Multigrade Super Engine Oil | SAE 15W40 API/SH/CD | | ‐20 to over 40° C | Ford Multigrade Super Engine Oil | SAE 10W30 API/SH/CD EC | | ‐20 to over 40° C | XR+ High‐performance High‐lubricity Engine Oil | SAE 10W40 API/SH/CD EC | | ‐30 to over 40° C | Ford Formula S Synthetic Engine Oil | SAE 5W50 API/SG/CD | | ‐30 to over 40° C | Synthetic/Semi‐synthetic Engine Oil | SAE 5W40 API/SH/CD EC | | 40 to below ‐30° C | Ford Multigrade Super Engine Oil | SAE 5W30 API/SG/CD | | The engine oil to specification SAE 5W30 API/SG/CD has only been approved for use in northern European territories | | If engine oils of other brands are used, it is imperative to ensure that these conform to API SG/CD or better in the particular viscosity class. | | General | | | | Hose clips | 4 | 3 | | Engine undershields to front crossmember | 19 | 14 | | Rear axle reinforcing bar | 49 | 36 | | Front axle reinforcing bar | 80 | 59 | | Front axle to side members | 80 | 59 | | Exhaust | | | | Exhaust system heat shield to cylinder head | 7 | 5 | | Exhaust mounting to transmission | 44 | 32 | | Exhaust mounting to transmission crossmember | 47 | 35 | | Exhaust bracket to engine | 47 | 35 | | Catalyst to exhaust manifold | 47 | 35 | | Inlet manifold | | | | Studs (coated with microcapsules) | 14 | 10 | | Inlet manifold nuts | 23 | 17 | | Throttle housing | 10 | 7 | | Idle air control (IAC) valve | 10 | 7 | | Exhaust manifold | | | | Studs (coated with microcapsules) | 17 | 13 | | Exhaust manifold nuts | 23 | 17 | | Exhaust gas recirculation (EGR) valve | 10 | 7 | | Transmission | | | | Earth lead to transmission | 44 | 32 | | Starter motor | 44 | 32 | | Engine/transmission flange bolts | 44 | 32 | | Bolt ‐ adaptor plate to transmission | 11 | 8 | | Driveshaft to rear axle | 66 | 49 | | Driveshaft centre bearing to floor assembly | 21 | 15 | | Driveshaft to vibration damper | 78 | 58 | | Oil dipstick tube | 10 | 7 | | Transmission crossmember to floor assembly | 36 | 27 | | Transmission crossmember to transmission | 62 | 46 | | Air conditioning system | | | | Compressor to cylinder block | 25 | 18 | | Coolant circuit | | | | Coolant pump | 23 | 17 | | Coolant temperature gauge sender unit | 6 | 4 | | Thermostat housing | 10 | 7 | | Engine coolant temperature (ECT) sensor | 12 | 9 | | Angle connector to water pump | 14 | 10 | | Water pump blanking plug | 16 | 12 | | Blanking cover for rear coolant outlet | 20 | 15 | | Steering | | | | Intermediate shaft to steering shaft | 18 | 13 | | Power steering pump to bracket | 23 | 17 | | Power steering pump pulley | 25 | 18 | | Engine mounting | | | | Engine mounting nuts | 50 | 37 | | Oil circuit | | | | Oil drain plug | 25 | 18 | | Oil pressure switch | 27 | 20 | | Oil filter mounting | 21 | 15 | | Oil filter | 14 | 10 | | Oil cooler | 60 | 44 | | Oil baffle to cylinder block | 21 | 15 | | Oil pump | 12 | 9 | | Oil intake pipe to cylinder block | 13 | 10 | | Sump to cylinder block (studs and nuts) | 12 | 9 | | Power steering | | | | Power steering pump to bracket | 25 | 18 | | Cylinder block | | | | Lower timing chain cover | 10 | 7 | | Rear oil seal housing | 13 | 10 | | Front oil seal housing | 26 | 19 | | Crankshaft position/speed sensor | 4 | 3 | | Timing chain guide rail, M6 | 12 | 9 | | Timing chain guide rail, M8 | 26 | 19 | | Crankcase breather | 9 | 7 | | Main bearing caps | 97 | 72 | | Big‐end bearing caps, stage 1 | 7 | 5 | | Big‐end bearing caps, stage 2 | 16 | 12 | | Big‐end bearing caps, stage 3 | 90° | 90° | | Crankshaft vibration damper, stage 1 | 52 | 38 | | Crankshaft vibration damper, stage 2 | 85° | 85° | | Flywheel | 87 | 64 | | Clutch pressure plate | 24 | 18 | | Oil pump chain tensioner arm | 12 | 9 | | Oil pump sprocket | 18 | 13 | | Cylinder Head | | | | Cylinder head, stage 1 | 10 | 7 | | Cylinder head, stage 2 | 35 | 26 | | Cylinder head, stage 3 | 90° | 90° | | Cylinder head, stage 4 | 90° | 90° | | Cylinder head cover, stage 1 | 3 | 2 | | Cylinder head cover, stage 2 | 9 | 7 | | Auxiliary cylinder head bolts (x3) | 38 | 28 | | Upper timing case cover | 11 | 8 | | Fuel rail | 24 | 18 | | Fuel pressure regulator | 10 | 7 | | Camshaft bearing caps | 24 | 18 | | Camshaft sprockets | 59 | 44 | | Engine lifting eyes | 25 | 18 | | Studs to cylinder head (x20) | 20 | 15 | | Blanking plugs | 52 | 38 | | Blanking cover for rear coolant outlet | 20 | 15 | | Spark plugs | 18 | 13 | | Ignition coils | 10 | 7 | |
