General Specifications
| Item | Specification |
|---|---|
| Lubricants and Sealants | |
| SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP | WSS-M2C153-H |
| Silicone Gasket and Sealant F7AZ-19554-EA | WSE-M4G323-A4 |
| Stud and Bearing Mount E0AZ-19554-BA | WSK-M2G349-A1 |
| Gasket Maker F8AZ-19B508-AB | WSK-M2G348-A5 |
| Engine | |
| Displacement | 2.0L (121 cubic inches) |
| Number of cylinders | 4 |
| Bore | 84.8 mm (3.34 in) |
| Stroke | 88.0 mm (3.46 in) |
| Firing order | 1-3-4-2 |
| Oil pressure (hot 4,000 RPM) | 370-550 kPa (54-80 psi) |
| Oil capacity (with filter) | 4.25 L (4.5 qts) |
| Compression ratio | 9.6:1 |
| Cylinder Head and Valve Train | |
| Cylinder head gasket surface flatness | 0.05/0.520/076 150 x 150 |
| Combustion chamber volume | |
| Valve arrangement (front to rear) | |
| Valve clearance - intake | 0.11-0.18 mm (0.004331-0.007087 in) |
| Valve clearance - exhaust | 0.27-0.34 mm (0.0106299-0.0133858 in) |
| Valve guide bore diameter (insert counterbore diameter) | 6.06 mm (0.23858 in) |
| Valve stem diameter | 6.03 mm (0.23740 in) |
| Valve stem-to-guide clearance | 0.017-0.064 mm (0.000662-0.0025196 in) |
| Valve head diameter - intake | 32.0 mm (1.2598 in) |
| Valve head diameter - exhaust | 28.0 mm (1.10236 in) |
| Valve face runout | 0.035 mm (0.0013779 in) |
| Valve face angle | 45 degrees |
| Valve seat width | |
| Valve seat runout | |
| Valve seat angle | |
| Valve spring free length | 43.2 mm (1.701 in) |
| Valve spring squareness | |
| Valve spring compression pressure - intake | 365 N (82.1 lb) @ 25.1 mm (0.988 in) |
| Valve spring compression pressure - exhaust | 422 N (94.94 lb) @ 26.1 mm (1.0275 in) |
| Valve spring installed height | 34.2 mm (1.346 in) |
| Valve spring installed pressure | |
| Roller follower ratio | |
| Camshaft | |
| Theoretical valve lift @ 0 lash - intake | 9.254 mm (0.3643 in) |
| Theoretical valve lift @ 0 lash - exhaust | 8.6 mm (0.33858 in) |
| Lobe lift - intake | 8.9 mm (0.3504 in) |
| Lobe lift - exhaust | 8.7 mm (0.3425 in) |
| Allowable lobe lift loss | |
| Journal diameter | 25.960-25.980 mm (1.0221-1.0227 in) |
| Camshaft journal bore inside diameter | |
| Camshaft journal-to-bearing clearance | |
| Runout | |
| End play | 0.080-0.220 mm (0.00315-0.00866 in) |
| Cylinder Block | |
| Cylinder bore diameter - standard | 84.807-84.823 mm (3.3389-3.3395 in) |
| Cylinder bore diameter - oversize | 85.060-85.070 mm (3.3488-3.3492 in) |
| Cylinder bore maximum taper | +0.025 mm (0.0009842 in)-0.013 mm (0.0005118 in) max. |
| Cylinder bore maximum out-of-round | 0.025 mm (0.0009842 in) max. |
| Main bearing bore inside diameter (bearing caps installed) | 58.011-58.0380 mm (2.28389-2.284956 in) |
| Main bearing bore inside diameter (bearing caps installed) - bearing caps graded by size | 58.008-58.031 mm (2.2837749-2.284680 in) |
| Head gasket surface flatness | |
| Crankshaft | |
| Main bearing journal diameter | 57.980-58.000 mm (2.2826726-2.28346 in) |
| Main bearing journal maximum taper | |
| Main bearing journal maximum out-of-round | |
| Main bearing journal-to-cylinder block clearance | |
| Connecting rod journal diameter | 46.89-46.91 mm (1.846059-1.850036 in) |
| Connecting rod journal maximum taper | |
| Connecting rod journal maximum out-of-round | |
| Crankshaft maximum end play | 0.09-0.26 mm (0.0035433-0.010236 in) |
| Piston and Connecting Rod | |
| Piston diameter - standard | 84.758-84.772 mm (3.3369-3.3375 in) |
| Piston diameter - oversize | 85.008-85.022 mm (3.3468-3.3473 in) |
| Piston-to-cylinder bore clearance | 0.035-0.065 mm (0.0014-0.0025 in) |
| Piston Ring End Gap | |
| Piston ring groove width - upper compression ring | 1.484 mm (0.058425 in) |
| Piston ring groove width - lower compression ring | 1.734 mm (0.0682675 in) |
| Piston ring groove width - oil control ring | 2.905 mm (1.1143698 in) |
| Piston ring width - upper and lower compression ring | 0.30-0.50 mm (0.011811-0.019685 in) |
| Piston ring width - oil control ring | 0.40-1.40 mm (0.015748-0.055118 in) |
| Piston ring-to-groove clearance | |
| Piston Pin Bore Diameter | |
| Piston pin diameter - white | 20.662-20.625 mm (0.8134629-0.8120062 in) |
| Piston pin diameter - red | 20.625-20.628 mm (0.8120062-0.8121243 in) |
| Piston pin diameter - blue | 20.628-20.631 mm (0.8121243-0.8122424 in) |
| Piston pin length | 63.00-63.80 mm (2.48031-2.51181 in) |
| Piston pin-to-piston fit | 0.010-0.015 mm (0.0003937-0.0005905 in) |
| Piston-to-connecting rod clearance | 0.016-0.049 mm (0.0006299-0.0019291 in) |
| Connecting rod-to-pin clearance | |
| Connecting rod pin bore diameter | 20.589-20.609 mm (0.810589-0.811376 in) |
| Connecting rod length | |
| Connecting rod maximum allowed bend | |
| Connecting rod maximum allowed twist | |
| Connecting rod bearing bore diameter | 46.89-46.91 mm (1.846059-1.846847 in) |
| Connecting rod bearing-to-crankshaft clearance | 0.016-0.070 mm (0.0006299-0.0027559 in) |
| Connecting rod side clearance | |
GENERAL SPECIFICATIONS
Torque Specifications
| Description | Nm | Lb-ft | Lb-in |
|---|---|---|---|
| A/C compressor bracket bolts | 24 | 18 | |
| A/C compressor bracket nuts | 48 | 35 | |
| Accessory drive belt idler pulley | 45 | 35 | |
| Battery cable nut (starter) | 12 | 9 | |
| Block heater screw | 3 | 27 | |
| Camshaft cap bolts | 19 | 14 | |
| Camshaft sprocket bolts | 68 | 50 | |
| Catalytic converter bracket bolts | 24 | 18 | |
| Cylinder head bolts (1) | |||
| Clutch pressure plate bolts (2) | 24 | 18 | |
| Clutch slave cylinder bolts | 22 | 16 | |
| Coil bracket bolts | 20 | 15 | |
| Coolant tube bolt/nut | 20 | 15 | |
| Coolant tube bracket bolt (oil cooler) | 10 | 89 | |
| Coolant tube stud | 24 | 18 | |
| Crankcase vent oil separator bolts | 10 | 89 | |
| Crankshaft rear oil seal housing bolts (1) | |||
| Crankshaft position sensor bolt | 8 | 71 | |
| Crankshaft pulley bolt | 115 | 85 | |
| Cylinder head temperature sensor | 10 | 89 | |
| Exhaust gas recirculation (EGR) tube nuts | 62 | 46 | |
| EGR tube bracket bolt | 10 | 89 | |
| EGR tube bracket bolt | 25 | 18 | |
| EGR tube bracket nut (lifting eye) | 25 | 18 | |
| Engine lifting eye nut (rear) | 15 | 11 | |
| Engine lifting eye bolt (front) | 35 | 26 | |
| Engine mount bolts/nut | 55 | 41 | |
| Engine mount ground wire nut (engine) | 9 | 80 | |
| Engine mount ground wire nut (body) | 10 | 89 | |
| Engine mount lower bracket bolts | 50 | 37 | |
| Engine mount bolts/nut | 34 | 25 | |
| Engine/transaxle mounting bolts | 45 | 33 | |
| Exhaust manifold bolts/nuts (2) | 16 | 12 | |
| Flywheel bolts | 112 | 83 | |
| Front transaxle mount through bolt | 90 | 66 | |
| Generator bolts | 45 | 33 | |
| Generator bracket bolt (upper) | 24 | 18 | |
| Generator bracket bolts/nut (lower) | 47 | 35 | |
| Generator wire nut | 8 | 71 | |
| Ground cable bolt (transaxle) | 9 | 80 | |
| Ground wire bolt (fender) | 9 | 80 | |
| Ground wire bolt (transaxle bracket) | 9 | 80 | |
| Inner timing belt cover bolts | 10 | 89 | |
| Intake manifold bolts/nuts (2) | 18 | 13 | |
| Knock sensor nut | 20 | 15 | |
| LH transaxle mount bolt (engine) | 90 | 66 | |
| LH transaxle mount bolts (body) | 55 | 41 | |
| Lower cylinder block bolts (2) | 30 | 22 | |
| Lower engine mount bracket bolts | 50 | 37 | |
| Lower engine mount bracket studs | 34 | 25 | |
| Lower timing belt cover bolts | 7 | 62 | |
| Lower splash shield bolts | 9 | 80 | |
| Oil cooler bolt | 58 | 43 | |
| Oil filter | 16 | 12 | |
| Oil level indicator and tube nut | 10 | 89 | |
| Oil pan bolts (1) | |||
| Oil pan drain plug | 25 | 18 | |
| Oil pressure sender | 27 | 20 | |
| Oil pump bolts (1) | |||
| Oil pump screen cover and tube bolts | 10 | 89 | |
| Powertrain control module (PCM) connector bolt | 6 | 53 | |
| PCM ground wire bolt | 9 | 80 | |
| Positive crankcase ventilation tube bolt | 10 | 89 | |
| Power distribution box cable nuts | 12 | 9 | |
| Power steering line bracket (pump) | 20 | 15 | |
| Power steering line bracket bolt (head) | 10 | 89 | |
| Power steering line bracket bolts (rack) | 10 | 89 | |
| Power steering line bracket bolts (body) | 10 | 89 | |
| Power steering pump bolts | 25 | 18 | |
| Power steering pump bracket bolts | 27 | 20 | |
| Rear transaxle mount bolts | 55 | 41 | |
| Shifter shaft bolt/nut | 20 | 15 | |
| Shifter strut rod bolt | 45 | 33 | |
| Speed control unit nuts | 10 | 89 | |
| Starter bolts | 25 | 18 | |
| Starter control wire nut | 5 | 44 | |
| Thermostat housing bolts | 20 | 15 | |
| Timing belt idler pulley bolt | 24 | 18 | |
| Timing belt tensioner bolt | 24 | 18 | |
| Upper timing belt cover bolts | 8 | 71 | |
| Valve cover bolts | 9 | 80 | |
| Coolant pump adapter bolts | 20 | 15 | |
| Coolant pump pulley bolts | 23 | 17 | |
| Wire harness connector bolt | 10 | 89 | |
| (1) Refer to the procedure for the tightening specifications. (2) Refer to the procedure for tightening sequences. | |||
| (1) | Refer to the procedure for the tightening specifications. |
| (2) | Refer to the procedure for tightening sequences. |
TORQUE SPECIFICATIONS
The 2.0L Zetec engine is a four cylinder in-line engine with double overhead camshafts and 16 valves. The 16 valve cylinder head improves volumetric efficiency, particularly at high engine speeds.
The cylinder head is made of aluminum alloy and the cylinder block is made of cast iron.
Scheme 517
The spark plug is installed in the center of the roof-shaped combustion chamber to ignite the air/fuel mixture in the combustion chamber. The central location of the spark plug causes the flame front to be evenly spread across the combustion chamber, which also reduces spark knock.
Both camshafts are driven by a shared timing belt, and operate four valves per cylinder by means of mechanical valve tappets. One valve spring on each valve is used to close the valve.
Scheme 518
Scheme 519
Scheme 520
Scheme 521
Scheme 522
Scheme 523
Scheme 524
| CAUTION | Only tension the timing belt counterclockwise. |
An automatic timing belt tensioner makes sure of correct timing belt tension. An additional spring-loaded cam provides proper belt tension during operation. The belt tensioner can operate 30 degrees either side of its central position.
The basic adjustment of the belt tensioner can no longer be controlled after the aligning tools and adjusting pin have been taken out (the spring forces from the valve train exert pressure on the timing belt and alter the position of the belt tensioner).
The 2.0L Zetec engine is equipped with a glass fiber-reinforced plastic intake manifold. The intake manifold ports are designed so the intake paths are the same length for all the cylinders.
- This gives the following advantages: reduced heat transfer to the injectors, thereby avoiding vapor locks lighter weight reduction of fuel deposits on the intake walls during cold starts less heating of the intake air when the engine is hot
The crankshaft runs on five bearings and has a counterweight for each cylinder. The central main bearing has two bearing half shells which guide the crankshaft along its axis as well as adjusting the end float.
Scheme 525
The connecting rods are numbered one to four starting at the timing belt end. It is practically impossible to mix up the connecting rod bearing caps and connecting rods since the connecting rod bearing caps are broken away from the connecting rod during production. The fracture profile of a connecting rod bearing cap therefore only fits one of the connecting rods.
Scheme 526
The EEC-V module manages the 2.0L Zetec engine. The module requires a large amount of information about the current operating conditions of the engine and, where appropriate, the automatic transaxle. The EEC-V module obtains this information by means of sensors.
The EEC-V module controls
- the fully electronic ignition system (EI)
- the sequential electronic fuel injection system (SFI)
- the air conditioning system together with the cooling system.
The purpose of the lower crankcase is to reduce engine vibrations. This further reduces the level of noise inside the vehicle. There is a metal gasket between the lower crankcase and the cylinder block.
Scheme 527
Lower crankcase spacer shims are used to even out any excessively large gaps between the transaxle and the lower crankcase (see SPECIFICATIONS ).
The engine is closed off at the bottom with a pressed steel oil pan which is directly attached to the lower crankcase. It is sealed with a 3 mm (0.12 in) wide bead of sealer.
For mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION .
For driveability concerns, refer to the SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV .
Scheme 528
See also:
• SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV