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303-01C Engine - 2.3L DOHC-16V > < Assembly|Installation|Engine

Transit 2000.5 (01.2000-05.2006)

Engine - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel - Specifications Transit 2000.5 (01/2000-05/2006)

Engine Data — 75 PS

Description
Code D3FA
Firing order 1-3-4-2
Bore diameter 86 mm
Stroke 86 mm
Displacement 1998 cc
Compression ratio 19:1
Power output at 3500 rpm 55 kW (75 PS)
Torque at 2000 rpm 185 Nm
Idle speed 800 rpm

Engine Data — 85 PS

Description
Code F3FA
Firing order 1-3-4-2
Bore diameter 86 mm
Stroke 86 mm
Displacement 1998 cc
Compression ratio 19:1
Power output at 3700 rpm 63 kW (85 PS)
Torque at 2100 rpm 200 Nm
Idle speed 800 rpm

Engine Data — 100 PS

Description
Code ABFA
Firing order 1-3-4-2
Bore diameter 86 mm
Stroke 86 mm
Displacement 1998 cc
Compression ratio 19:1
Power output at 4000 rpm 74 kW (100 PS)
Torque at 2300 rpm 230 Nm
Idle speed 800 rpm

Engine Data — 125 PS

Description
Code FIFA
Firing order 1-3-4-2
Bore diameter 86 mm
Stroke 86 mm
Displacement 1998 cc
Compression ratio 19:1
Power output at 4000 rpm 92 kW (125 PS)
Torque at 2300 rpm 280 Nm
Idle speed 800 rpm

Engine Oil Capacity

Description Liters
Initial fill including oil filter 6.72
Service fill including oil filter 6.40

Cylinder Block Dimensions

Description mm
Cylinder bore diameter — Class 1 86.000 - 86.010
Cylinder bore diameter — Class 2 86.010 - 86.020
Cylinder bore diameter — Class 3 86.020 - 86.030
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 0.033 - 0.080
Main bearing 5 radial clearance 0.034 - 0.083
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 85.94 - 85.95
Piston diameter — Class 2 85.95 - 85.96
Piston diameter — Class 3 85.96 - 85.97
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 gaps must be distributed evenly around the circumference of the piston. This also applies to the oil control ring elements. Align the piston ring 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 66.700
Piston pin diameter 30.000
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 - 75/85 and 100 PS engine

Description mm
Maximum distortion — measured longitudinally and diagonally 0.10
Peak to valley height of mating surface 0.02
Thickness of cylinder head gasket with piston protrusion of 0.300 - 0.400 mm 1.1 (one hole/tooth)
Thickness of cylinder head gasket with piston protrusion of 0.401 - 0.450 mm 1.15 (two hole/teeth)
Thickness of cylinder head gasket with piston protrusion of 0.451 - 0.500 mm 1.2 (three holes/teeth)

Cylinder Head Dimensions - 125 PS engine

Description mm
Maximum distortion — measured longitudinally and diagonally 0.10
Peak to valley height of mating surface 0.02
Thickness of cylinder head gasket with piston protrusion of 0.430 - 0.520 mm 1.1 (one hole/tooth)
Thickness of cylinder head gasket with piston protrusion of 0.521 - 0.570 mm 1.15 (two hole/teeth)
Thickness of cylinder head gasket with piston protrusion of 0.571 - 0.620 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
Accessory drive belt idler pulley retaining bolts 53 39 –
Transaxle retaining bolts 40 30 –
Engine rear mount retaining nut 150 111 –
Engine front mount retaining nut 150 111 –
Engine front mount to engine mount retaining bolts 103 76 -
Engine front mount to side member retaining bolts 70 52 -
Engine support insulator to transaxle bolts 103 76 –
Engine support insulator to front axle crossmember bolts 23 17 –
Lower arm ball joint retaining nuts 150 113 –
Halfshaft centre bearing cap locknuts 25 18 –
Tie-rod end retaining nut 80 59 –
Engine ground cable retaining bolt 13 10 –
Radiator support bracket retaining bolts 9 – 80
Stub lever retaining bolts 12 9 –
Valve cover retaining nuts and bolts 10 – 89
Thermostat housing retaining bolts 23 17 –
Crankshaft pulley retaining bolts a) – –
Crankshaft rear oil seal carrier retaining bolts 10 – 89
Flywheel retaining bolts a) – –
Crankshaft main bearing cap retaining bolts a) – –
Connecting rod bearing cap retaining bolts a) – –
Fuel injectors (115 PS engine) 47 35 –
Fuel injectors (75/85 and 100 PS engine) 52 38 -
Fuel supply line retaining bolt 6 – 53
Coolant outlet and degas connector to engine bolts 22 16 –
Fuel injection pump sprocket retaining bolts 32 24 –
Fuel injection pump retaining bolts 22 16 –
High-pressure fuel supply line unions 40 30 –
Fuel injector return line unions 8 – 71
Ladder frame retaining bolts a) – –
Coolant distribution manifold retaining bolts 10 – 89
Clutch disc and pressure plate 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 –
Brake vacuum pump retaining bolts 22 16 –
Camshaft sprocket retaining bolts 33 24 –
Camshaft pulley retaining bolt 64 47 –
Accessory drive belt tensioner bracket retaining bolts 23 17 –
Exhaust gas recirculation (EGR) valve retaining bolt 23 17 –
EGR cooler to exhaust manifold bolts 10 – 89
EGR cooler to EGR valve tube bolts 22 16 –
Exhaust manifold to EGR valve tube retaining bolt 10 – 89
Water pump retaining bolts 23 17 –
Water drain panel retaining bolts 12 9 –
Windshield wiper motor bracket retaining bolts 12 9 –
Windshield wiper arm retaining nuts 22 16 –
Hood retaining bolts 24 18 –
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) – –
Oil level indicator tube retaining bolt 22 16 –
Cylinder head bolts a) – –
Engine front cover retaining bolts 14 10 –
Engine front cover retaining nuts 10 – 89
Exhaust manifold studs 20 15 –
Glow plugs 12 9 –
Generator mounting bracket retaining bolts 22 16 –
Power steering pump retaining bolts 18 14 –
Power steering pump mounting bracket retaining bolts 23 17 –
Intake manifold retaining bolts 16 12 –
Turbocharger and exhaust manifold assembly retaining bolts 40 30 –
Turbocharger oil return tube retaining bolts 10 – 89
Turbocharger oil supply tube union bolt 13 10 –
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 bolts 5 – 44
Turbocharger heat shield retaining bolts 10 – 89
Catalytic converter support bracket retaining bolts 25 18 –

a) Refer to the procedure in this section.

Lubricants, Fluids, Sealers and Adhesives

Item Specification
Ford Formula E SAE 5W-30 engine oil WSS-M2C913-A
Sealer — oil pan, camshaft carrier and engine front cover WSE-M4G323-A4

303-01C Engine - 2.3L DOHC-16V > < Assembly|Installation|Engine