Ford Workshop Service and Repair Manuals

Engine Data — 75 PS

Description
Code	F4FA
Firing order	1-3-4-2
Bore diameter	89.9 mm
Stroke	94.6 mm
Displacement	2402 cc
Compression ratio	19:1
Power output at 3500 rpm	55 kW (75 PS)
Torque at 2000 rpm	185 Nm
Idle speed	800 rpm
Maximum permissible engine speed — continuous	4900 rpm
Maximum permissible engine speed — intermittent	4900 rpm
Maximum oil consumption	0.1L / 1000 Km

Engine Data — 90 PS with Exhaust Gas Recirculation (EGR) and automated shift mechanism (ASM)

Description
Code	D2FA
Firing order	1-3-4-2
Bore diameter	89.9 mm
Stroke	94.6 mm
Displacement	2402 cc
Compression ratio	19:1
Power output at 4000 rpm	66 kW (90 PS)
Torque at 1800 rpm	200 Nm
Idle speed	850 rpm
Maximum permissible engine speed — continuous	4900 rpm
Maximum permissible engine speed — intermittent	4900 rpm
Maximum oil consumption	0.1L / 1000 Km

Engine Data — 90 PS with Exhaust Gas Recirculation (EGR)

Description
Code	D2FB
Firing order	1-3-4-2
Bore diameter	89.9 mm
Stroke	94.6 mm
Displacement	2402 cc
Compression ratio	19:1
Power output at 4000 rpm	66 kW (90 PS)
Torque at 1800 rpm	220 Nm
Idle speed	850 rpm
Maximum permissible engine speed — continuous	4900 rpm
Maximum permissible engine speed — intermittent	4900 rpm
Maximum oil consumption	0.1L / 1000 Km

Engine Data — 90 PS without EGR

Description
Code	HEFA
Firing order	1-3-4-2
Bore diameter	89.9 mm
Stroke	94.6 mm
Displacement	2402 cc
Compression ratio	19:1
Power output at 4000 rpm	66 kW (90 PS)
Torque at 1600 rpm	210 Nm
Idle speed	850 rpm
Maximum permissible engine speed — continuous	4600 rpm
Maximum permissible engine speed — intermittent	4600 rpm
Maximum oil consumption	0.1L / 1000 Km

Engine Data — 115 PS

Description
Code	FXFA
Firing order	1-3-4-2
Bore diameter	89.9 mm
Stroke	94.6 mm
Displacement	2402 cc
Compression ratio	19:1
Power output at 3500 rpm	85 kW (115 PS)
Torque at 2000 rpm	185 Nm
Idle speed	850 rpm
Maximum permissible engine speed — continuous	4900 rpm
Maximum permissible engine speed — intermittent	4900 rpm
Maximum oil consumption	0.1L / 1000 Km

Engine Data — 120 PS with EGR

Description
Code	D4FA
Firing order	1-3-4-2
Bore diameter	89.9 mm
Stroke	94.6 mm
Displacement	2402 cc
Compression ratio	19:1
Power output at 4000 rpm	88 kW (120 PS)
Torque at 2300 rpm	240 Nm
Idle speed	800 rpm
Maximum permissible engine speed — continuous	4900 rpm
Maximum permissible engine speed — intermittent	4900 rpm
Maximum oil consumption	0.1L / 1000 Km

Engine Data — 120 PS without EGR

Description
Code	HFFA
Firing order	1-3-4-2
Bore diameter	89.9 mm
Stroke	94.6 mm
Displacement	2402 cc
Compression ratio	19:1
Power output at 4000 rpm	88 kW (120 PS)
Torque at 1800 rpm	245 Nm
Idle speed	850 rpm
Maximum permissible engine speed — continuous	4600 rpm
Maximum permissible engine speed — intermittent	4600 rpm
Maximum oil consumption	0.1L / 1000 Km

Engine Data — 125 PS

Description
Code	DOFA
Firing order	1-3-4-2
Bore diameter	89.9 mm
Stroke	94.6 mm
Displacement	2402 cc
Compression ratio	19:1
Power output at 3500 rpm	92 kW (125 PS)
Torque at 2000 rpm	185 Nm
Idle speed	850 rpm
Maximum permissible engine speed — continuous	4900 rpm
Maximum permissible engine speed — intermittent	4900 rpm
Maximum oil consumption	0.1L / 1000 Km

Engine Data — 135 PS

Description
Code	H9FA
Firing order	1-3-4-2
Bore diameter	89.9 mm
Stroke	94.6 mm
Displacement	2402 cc
Compression ratio	19:1
Power output at 3500 rpm	101 kW (135 PS)*
Torque at 2000 rpm	185 Nm
Idle speed	850 rpm
Maximum permissible engine speed — continuous	4900 rpm
Maximum permissible engine speed — intermittent	4900 rpm
Maximum oil consumption	0.1L / 1000 Km

* The engine is marketed as 135 PS, the actual power is 137 PS.

Engine Oil Capacity

Description	Liters
Initial fill including oil filter	7.00
Service fill including oil filter	6.50

Cylinder Block Dimensions

Description	mm
Cylinder bore diameter — Class 1	89.900 - 89.910
Cylinder bore diameter — Class 2	89.910 - 89.920
Cylinder bore diameter — Class 3	89.920 - 89.930
Main bearing shells 1 to 4 inner diameter — bearings installed	65.003 - 65.030
Main bearing shell 5 inner diameter — bearings installed	70.004- 70.033
Main bearings 1 to 4 radial clearance	0.005 - 0.051
Main bearing 5 radial clearance	0.004 - 0.054
Main bearings 1 to 4 parent bore diameter — vertical measurement	69.504 - 64.520
Main bearing 5 parent bore diameter — vertical measurement	74.504 - 74.520
Main bearings 1 to 4 parent bore diameter — horizontal measurement	69.502 - 69.525
Main bearing 5 parent bore diameter — horizontal measurement	74.502 - 74.525

Piston Dimensions

Description	mm
Piston diameter — Class 1	89.84 - 89.85
Piston diameter — Class 2	89.85 - 89.86
Piston diameter — Class 3	89.86 - 89.87
Piston clearance in cylinder	0.05 - 0.07
Piston ring end gaps
— upper compression ring	0.25 - 0.50
— lower compression ring	0.50 - 0.75
— oil control ring	0.25 - 0.50

Piston ring gap position: The piston ring end gaps must be distributed evenly around the circumference of the piston. This also applies to the oil control ring elements. Align the piston ring end gaps at 120 degrees to each other.

Crankshaft Dimensions

Description	mm
Main bearing journal end float	0.090 - 0.305
Main bearing journals 1 to 4 diameter	64.950 - 64.970
Main bearing journal 5 diameter	69.950 - 69.970
Connecting rod bearing journal diameter	52.980 - 53.000

Connecting Rod Dimensions

Description	mm
Large end bore diameter	55.096 - 56.015
Small end bore diameter	30.010 - 30.018
Connecting rod bearing shell inner diameter — bearings installed	53.017 - 53.043
Connecting rod bearing radial clearance	0.034 - 0.100
Connecting rod bearing axial clearance	0.100 - 0.320

Piston Pin Dimensions

Description	mm
Piston pin length	65.850 - 66.150
Piston pin diameter	32.000 - 31.996
Piston pin slide clearance	0.002 - 0.012

Camshaft Dimensions

Description	mm
Camshaft end float	0.125
Camshaft bearing journal diameter	26.450
Camshaft bearing clearance — radial measurement	0.065

Valve Dimensions

Description	mm
Valve stem to valve guide clearance — intake valve	0.045
Valve stem to valve guide clearance — exhaust valve	0.055

Cylinder Head Dimensions

Description	mm
Maximum distortion — measured longitudinally and diagonally	0.10
Peak to valley height of mating surface	0.02
Cylinder head gasket thickness
Piston protrusion of 0.310 - 0.400 mm	1.1 (one hole/tooth)
Piston protrusion of 0.401 - 0.450 mm	1.15 (two holes/teeth)
Piston protrusion of 0.451 - 0.500 mm	1.2 (three holes/teeth)

Oil Pressure Specifications

Description	bar
Minimum oil pressure at idle speed	1.25
Minimum oil pressure at 2000 rpm	2.0

Torque Specifications

Description	Nm	lb-ft	lb-in
Transmission retaining bolts	40	30	–
Engine crossmember support bracket to engine block retaining bolts (vehicles with 75 PS, 90 PS, 115 PS, 120PS, or 125 PS engine)	40	30	–
Engine crossmember support bracket to engine block retaining bolts (vehicles with 135 PS engine)	63	46	-
Engine support insulator retaining nuts (vehicles with 75 PS, 90 PS, 115 PS, 120PS, or 125 PS engine)	103	76	–
Engine support insulator retaining nuts (vehicles with 135 PS engine)	80	59	-
Vibration damper to engine crossmember bolt	80	59	–
Driveshaft to transmission output shaft flange bolts (Vehicles built up to 10/2001)	80	59	–
Driveshaft to transmission output shaft flange bolts (vehicles built 10/2001 onwards, with 5-speed manual transmission)	115	85	-
Driveshaft to transmission output shaft flange bolts (vehicles built 10/2001 onwards, with 6-speed manual transmission)	175	129	-
Engine crossmember retaining bolts	70	52	–
Transmission support insulator to front axle crossmember bolts	40	30	–
Transmission support insulator to transmission retaining bolt (vehicles with 75 PS, 90 PS, 115 PS, 120PS, or 125 PS engine)	63	46	-
Transmission support insulator to transmission retaining bolt(vehicles with 135 PS engine)	70	52	-
Engine ground cable to side member bolt	15	11	–
Jump start point to starter motor solenoid cable retaining nut	12	9	–
Engine wiring harness electrical connector retaining bolt	7	–	62
Radiator support bracket retaining bolts	9	–	80
Stub lever retaining bolts	12	9	–
Valve cover retaining nuts and bolts	10	–	89
Thermostat housing retaining bolt	22	16	–
Thermostat housing support bracket retaining bolts	23	17	–
Crankshaft pulley retaining bolts	a	–	–
Crankshaft rear oil seal carrier retaining bolt	10	–	89
Flywheel retaining bolts	a	–	–
Crankshaft main bearing cap retaining bolts	a	–	–
Connecting rod bearing cap retaining bolts	a	–	–
Fuel injectors	52	38	–
Fuel injection pump retaining bolts	22	16	–
Fuel injection pump sprocket retaining bolts	32	24	–
High-pressure fuel supply line unions - vehicles with EGR	35	26	–
High-pressure fuel supply line unions - vehicles without EGR	25	18	–
Fuel injector return line unions	8	–	71
Ladder frame retaining bolts	a	–	–
Camshaft carrier retaining bolts	a	–	–
Rocker shaft retaining bolts	a	–	–
Timing chain guide retaining bolts	15	11	–
Timing chain tensioner retaining bolts	15	11	–
Oil pump chain tensioner retaining bolts	16	12	–
Camshaft sprocket retaining bolts	33	24	–
Accessory drive belt tensioner bracket retaining bolts	22	16	–
Generator retaining bolts	48	35	–
Generator mounting bracket retaining bolts	22	16	–
EGR valve retaining bolt	10	–	89
Exhaust manifold to EGR valve tube retaining bolts	20	15	–
Intake manifold tube retaining bolts	16	12	–
Fuel injection pump vacuum line union	18	13	–
Water pump retaining bolts	23	17	–
Coolant outlet and degas connector to engine bolt	22	16	–
Water drain panel retaining bolts	12	9	–
Windshield wiper motor bracket retaining bolts	12	9	–
Windshield wiper arm retaining nuts	22	16	–
Oil level indicator tube retaining bolts	22	16	–
Oil pump pickup tube retaining bolts	10	–	89
Oil cooler retaining bolts	23	17	–
Oil pump retaining bolts	a	–	–
Oil pan drain plug	23	17	–
Oil pressure switch	15	11
Oil pan retaining bolts	a	–	–
Coolant distribution manifold retaining bolts	10	–	89
EGR cooler to cylinder head bolts	23	17	–
Cylinder head bolts	a	–	–
Engine front cover retaining bolts	14	11	–
Engine front cover retaining nuts	10	–	89
Accessory drive belt idler pulley retaining bolts	53	39	–
Cooling fan pulley retaining bolts	53	39	–
Glow plugs	12	9	–
Power steering pump retaining bolts	23	17	–
Power steering pump mounting bracket retaining bolts	22	16	–
Intake manifold retaining bolts	16	12	–
Exhaust manifold retaining bolts	40	30	–
Exhaust manifold studs	20	15	–
Turbocharger oil return tube retaining bolts	10	–	89
Turbocharger oil supply tube union	9	–	80
Engine front lifting eye retaining bolt	23	17	–
Crankshaft position sensor (CKP) retaining bolt	7	–	62
Cylinder head temperature (CHT) sensor retaining bolt	10	–	89
Wiring loom retaining bolt	5	–	44
Front under-run bar retaining bolts — 4.25 tonne chassis single cab	50	37	–

a) Refer to the procedure in this section.

Lubricants, Fluids, Sealers and Adhesives

Item	Specification
Ford Formula E SAE 5W-30 engine oil - vehicles with exhaust gas recirculation (EGR)	WSS-M2C913-A
SAE 10W-30 engine oil - vehicles without EGR	WSS-M2C921-A
Sealer — oil pan, camshaft carrier and engine front cover	WSE-M4G323-A4