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Transit 1995 (08.1994-07.2000)

Mechanical Repairs > 3 Powertrain > 321 Basic Engine > 321-04 2,5 Turbocharged-TCI Diesel Engine (85 PS) > SpecificationsGeneral Specifications

General SpecificationsTransit 1995 (08/1994-07/2000)
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Specifications
Engine Data
General
Identification code'95 model year4GA
Identification code, vehicles up to 2,8 t'95 model year4GC
Identification code, LDT (light commercial  vehicles)'95 model year4GB
Identification code, 2,5 TCI diesel engine'97 model year4GD
Identification code, LDT (light commercial  vehicles)'97 model year4GE
Emission standard: 4GAA13
Emission standard: 4GC93 EEC
Emission standard: 4GB95/97 EEC
Emission standard: 4GD96 EEC
Emission standard: 4GE97 EEC
Injection sequence (cylinders numbered from front to rear)1‐2‐4‐3
Bore93,67 mm
Stroke90,54 mm
Cubic capacity 2496 cc
Compression ratio19,0 : 1
Power output (EEC)63 kW
Power output (EEC)85 PS
Power output (EEC)at rev/min4000
Torque (EEC)200 Nm
Torque (EEC)at rev/min2100
Idle speed850 ± 25
Max. permissible engine speedContinuous rev/min4000
Maximum permissible engine speedIntermittent rev/min4400
Dimensions
Cylinder blockDimensions in mm
Bore diameterClass 1.93,648 ‐ 93,660
Class 2.93,660 ‐ 93,672
Class 3.93,672 ‐ 93,684
Class 4.93,684 ‐ 93,696
Measuring point80 mm below cylinder head mating face
Main bearing bore in the cylinder block ‐ rearClass A81,00 ‐ 81,02
Class B81,40 ‐ 81,42
Main bearing bore in the cylinder block ‐ othersClass A74,00 ‐ 74,02
Class B74,40 ‐ 74,42
Camshaft bearing bore in cylinder blockStandard61,000 ‐ 61,046
Oversize61,500 ‐ 61,546
Pistons
Number of piston ringsCompression rings2
Oil scraper ring1
Ring groove widthUpper compression ring2,13 ‐ 2,15
Lower compression ring2,070 ‐ 2,095
Oil scraper ring4,030 ‐ 4,055
Piston pin bore:Orange29,002 ‐ 29,006
Black29,006 ‐ 29,010
Standard piston ØClass 1.93,621 ‐ 93,633
Class 2.93,633 ‐ 93,645
Class 3.93,645 ‐ 93,657
Class 4.93,657 ‐ 93,669
Piston clearance in bore0,015 ‐ 0,039
Height of measuring point for piston clearance in bore, measured from the piston crown at right angles to the piston pin bore81,5
Piston oversize0,65 and 1,00
Piston protrusion relative to cylinder block face at TDC, in production0,201 ‐ 0,403
Piston pins
Outside dia.Orange28,996 ‐ 29,000
Outside dia.Black29,000 ‐ 29,004
Piston pin length79,000 ‐ 79,400
Clearance in piston pin bore (selective fit)0,002 ‐ 0,010
Piston rings
Ring gaps:Upper compression ring0,40 ‐ 0,65
Dimensions
Dimensions in mm
Ring gaps:Lower compression ring0,40 ‐ 0,65
Oil scraper ring0,25 ‐ 0,58
Upper compression ring0,25 ‐ 0,50
Lower compression ring0,25 ‐ 0,50
Oil scraper ring0,25 ‐ 0,58
Ring widths:Upper compression ring2,313 ‐ 2,333
Lower compression ring1,975 ‐ 1,990
Oil scraper ring3,978 ‐ 3,990
Lateral clearance in grooves: Upper compression ring0,14 ‐ 0,172
Lower compression ring0,06 ‐ 0,092
Oil scraper ring0,02 ‐ 0,052
Dimensions
Connecting rods and big‐end bearingsDimensions in mm
Connecting rod length between bore centres:1A153,862 ‐ 153,931
2A153,931 ‐ 154,000
3A154,000 ‐ 154,069
4A154,069 ‐ 154,138
Piston pin bush bore29,010 ‐ 29,022
Piston pin clearance0,006 ‐ 0,026
Big‐end bore without bearing shells63,506 ‐ 63,520
Bearing shell oversizes1,738 ‐ 1,729
Bearing shell thickness (standard)0,125; 0,25; 0,375; 0,5
Bearing shell width25,87 ‐ 26,13
Big‐end bearing clearance0,030 ‐ 0,095
End float on big‐end bearing journal0,140 ‐ 0,420
Max. ovality of big‐end bearing journal0,025
Max. ovality of big‐end bearing journalwhen already re‐worked0,010
Dimensions
Crankshaft and main bearingsDimensions in mm
Number of main bearing journals5
Main bearing journal dia.: RearSize 1 mm76,980 ‐ 77,000
Size 2 mm76,730 ‐ 76,750
Main bearing journal dia.: OthersSize 1 mm69,980 ‐ 70,000
Size 2 mm69,730 ‐ 69,750
Regrind undersize (nominal, service diameter): ‐ RearSize 3 mm76,490 ‐ 76,500
Size 4 mm69,490 ‐ 69,500
Regrind undersize (nominal, service diameter): OthersSize 3 mm76,240 ‐ 76,250
Size 4 mm69,240 ‐ 69,250
Main bearing journal length (centre)35,625 ‐ 35,675
Crankshaft end float0,075 ‐ 0,325
Main bearing clearance:Nos. 1 to 40,052 ‐ 0,090
No. 50,056 ‐ 0,094
Number of teeth on driving gear and timing belt pulley on crankshaft:Oil pump driving gear32 teeth
Timing belt pulley24 teeth
Maximum turning torques:Crankshaft on its own (without connecting rods and pistons)2,9 Nm
Crankshaft (with rear oil seal, connecting rods and pistons; without  cylinder head and  timing cover)50 Nm
CamshaftInlet7,3
Exhaust7,6
Number of bearings5
Bearing journal diameter55,966 ‐ 55,941
Bearing bore56,032 ‐ 56,058
Bearing clearance0,072 ‐ 0,116
Oversize bearings (outside diameter)0,50
Camshaft end float0,10 ‐ 0,25
Dimensions
Oil pumpDimensions in mm
Driving gear backlash0,050 ‐ 0,330
Inner/outer rotor clearance0,150 max.
Outer rotor/housing clearance0,13 ‐ 0,30
Rotor end float0,01 ‐ 0,09
Oil pressure:New engine  (idle speed)1,0 bar
Normal operation2,7 ‐ 4,8 bar
Dimensions
FlywheelDimensions in mm
Max. friction face run‐out0,130 at radius of 120
Dimensions
Cylinder headDimensions in mm
Valve guide length ‐ inlet and exhaust56,50
Valve guide dia. ‐ inlet and exhaust:Outside dia.14,738 ‐ 14,725
Inside dia.8,982 ‐ 9,013
Valve guide protrusion relative to cylinder head cover mating face1,80 ‐ 2,30
Valve seat rings (when fitted), recess dia.:Inlet43,50 ‐ 43,54
Exhaust37,96 ‐ 38,00
Recess depth ‐ inlet and exhaust9,00 ‐ 9,15
Valve seat angle relative to horizontal:Inlet30° ‐ 30°30'
Exhaust45° ‐ 45°30'
Valve head depth in cylinder head:Inlet0,35 ‐ 0,65
Exhaust0,50 ‐ 0,80
Recess dia.Inlet43,50 max.
Exhaust37,96 max.
Depth (both)9,00 max.
Dimensions
ValvesDimensions in mm
Valve head dia.Inlet41,90 ‐ 42,10
Exhaust36,20 ‐ 36,40
Valve head seat angle:Inlet29°30' ‐ 30°
Exhaust44°30' ‐ 30°
Stem dia.Inlet8,941 ‐ 8,966
Exhaust8,923 ‐ 8,948
Stem clearance:Inlet0,010 ‐ 0,066
Exhaust0,024 ‐ 0,084
Valve spring identification colourInletRed
ExhaustGreen and yellow
Dimensions
Rocker shaft and rocker armsDimensions in mm
Rocker shaft diameter18,87 ‐ 18,90
Number of springs on rocker shaft4
Spring length (compressed)25,4
Spring force (compressed)17 ‐ 21 N
Rocker arm clearance on shaft0,02 ‐ 0,08
Dimensions
Push rods and tappets
Push rod length154,87 ‐ 153,87
Push rod dia.7,72 ‐ 8,03
Tappet stem dia.17,475 ‐ 17,488
66,10 ‐ 66,85
Dimensions
Valve timing and valve clearanceDimensions in mm
Nominal valve timings with clearance of 0,5 mm:Inlet valve opens5° before TDC
Inlet valve closes27° after BDC
Exhaust valve opens57° before TDC
Exhaust valve closes7° after TDC
Valve lift:Inlet9,12
Exhaust10,81
Valve clearance (warm or cold):Inlet0,20
Exhaust0,38
Dimensions
Drive belt tension, alternator, coolant pump, crankshaft, fan
New beltBelt tension:578 ‐ 423 N
Deflection:4,5 mm
New belt after 15 minutes' runningBelt tension:378 ‐ 423 N
Deflection:5,5 mm
Used belt (used for less than 10 minutes)378 ‐ 423 N
Paint mark at three pointsGreen
Dimensions
V‐belt tension, power steeringMeasurement in N
New belt578 ‐ 623
New belt after 15 minutes' running378 ‐ 423
Used belt378 ‐ 423
Paint mark at three pointsGreen
Main bearing shell thickness ‐ in production
Colour of build data plateSize classBearingsBearing shell identification  colourBearing shell thickness in mm
Blue1ARearRed1,972 ‐ 1,963
Blue1,982 ‐ 1,973
OthersRed1,974 ‐ 1,965
Blue1,984 ‐ 1,975
Gold2ARearRed/white2,097 ‐ 2,088
Orange/blue2,107 ‐ 2,098
OthersRed/white2,099 ‐ 2,090
Orange/blue2,109 ‐ 2,100
Red2BRearWhite2,297 ‐ 2,288
Orange2,307 ‐ 2,298
OthersWhite2,290 ‐ 2,295
Orange2,309 ‐ 2,300
Service main bearing shells (in sets)
Cylinder block sizeCrankshaft sizeSizeBearing shell  colour code
A11ATop red  Bottom blue
2; re‐ground2AOne class  No colour
3; re‐ground3AOne class  No colour
4; re‐ground4AOne class  No colour
B11BOne class  No colour
2; re‐ground2BTop white  Bottom orange
3; re‐ground3BOne class  No colour
4; re‐ground4BOne class  No colour
Big‐end bearing shells ‐ available for following crankshaft sizes
SizeBig‐end bearing journal dia. in mmBearing shell thickness in mm
160,001,729
259,751,854
359,501,988
459,252,113
Lubricants, Adhesives, Coolants and Sealers
DescriptionFord Specification
Grease for input shaft splines and sliding face of clutch release bearing on guide sleeveESDM‐1C220‐A
Grease for timing belt tensioner mounting faceSM1C‐4515‐A
Thread‐locking compound ‐ Loctite 270SDM‐4G‐9107‐A
Sealer ‐ non‐hardening ‐ Hylomar PL32MSPM‐4G‐9112‐F
Super‐Plus 4 Coolant ConcentrateESD‐M97B‐49‐A
Capacity
DescriptionLitres
Engine oil ‐ initial fill incl. filter7
Engine oil ‐ oil change without filter change5,75
Engine oil ‐ oil change incl. filter change6
Coolant11,6
Engine oil
Viscosity / Ambient temperatureDesignationSpecification
Recommended engine oil:
SAE 10W30 / ‐20 to over  40 degrees CentigradeFord Super Multigrade Engine OilACEA A2‐96/B2‐96 or A3‐96/B3‐96 or API/SH/CD EC
Alternative engine oils:
SAE 5W40 / ‐20 to over  40 degrees CentigradeFord Formula S Synthetic Engine OilACEA A3‐96/B3‐96 or  API/SH/CD EC
SAE 10W40 / ‐20 to over  40 degrees CentigradeFord XR+ High‐performance High‐lubricity Engine OilACEA A3‐96/B3‐96 or API/SH/CD EC
SAE 15W40 / ‐15 to over  40 degrees CentigradeFord Super Multigrade Engine OilACEA A2‐96/B2‐96 or A3‐96/B3‐96 or API/SG/CD
SAE 5W30 / ‐20 to over 10°C Ford Formula E Economy Engine OilACEA A1‐96/B1‐96 and WSS‐M2C912‐A1

NOTE:

The engine oil to specification SAE 5W30 has only been approved for use in northern European territories.

If engine oils with these specifications are not available, use only engine oils which conform to specifications API SH/CD EC and CCMC PD2 or better.
Torques
GeneralNmlbf.ft
Bracket of front exhaust pipe2418
Lock panel to radiator118
Support brace to crossmember118
Radiator grille118
Torques
Exhaust manifoldNmlbf.ft
Exhaust manifold to cylinder head4735
Front exhaust pipe to exhaust manifold5037
Front exhaust pipe to rear exhaust pipe3828
Torques
AlternatorNmlbf.ft
Drive belt tensioning bracket2317
Alternator mounting bolt2317
Torques
SteeringNmlbf.ft
Clamp bolt of steering intermediate shaft3022
Steering gear to crossmember5037
Torques
Exhaust gas recirculation (EGR)Nmlbf.ft
EGR cooler bracket2317
EGR cooler2317
EGR pipe to exhaust manifold2317
Torques
Engine mountingsNmlbf.ft
Engine mounting bracket to cylinder block5541
Engine mounting bracket to transmission6246
Engine mounting nuts5037
Torques
Fuel SystemNmlbf.ft
Fuel pump heat shield2317
Fuel filter1712
Fuel injection pipes1914
Torques
Transmission and driveshaftNmlbf.ft
Driveshaft centre bearing to floor assembly3324
Driveshaft to transmission8462
Gear lever to transmission housing2519
Transmission to engine3526
Fuel line bracket to transmission flange3526
Clutch housing front cover2519
Clutch housing adaptor plate107
Transmission to rear transmission mounting8462
Bolt/nut of rear transmission mounting to transmission crossmember8462
Starter motor to transmission flange3526
Starter motor earth lead to transmission flange3526
Torques
Cylinder blockNmlbf.ft
Cylinder head to cylinder block ‐ Stage 17052
Cylinder head to cylinder block ‐ Stage 27052
Cylinder head to cylinder block ‐ Stage 390°90°
Crankshaft rear oil seal housing to cylinder block1914
Allen screws ‐ rear oil seal housing 1410
Flywheel to crankshaft ‐ Stage 12115
Flywheel to crankshaft ‐ Stage 230°30°
Timing belt cover to adaptor plate75
Clutch pressure plate to flywheel3022
Torques
Cylinder headNmlbf.ft
Cylinder head cover ‐ Stage 175
Cylinder head cover ‐ Stage 275
Rocker shaft bearing pedestal bolts, M82921
Rocker shaft bearing pedestal bolts, M106649
Rocker arm adjusting bolt, min.129
Rocker arm adjusting bolt, max.4835
Bolt ‐ injector retaining plate4030
Thermostat housing to cylinder head2317
Temperature gauge sender unit1511
Engine lifting eye2317
Bracket for supporting engine lifting bracket2317

Mechanical Repairs > 3 Powertrain > 321 Basic Engine > 321-04 2,5 Turbocharged-TCI Diesel Engine (85 PS) > SpecificationsGeneral Specifications

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